Maintenance system for industrial robot

Abstract

To provide a maintenance system of an industrial robot capable of returning the industrial robot after finishing maintenance work to a posture before starting the maintenance work.SOLUTION: The maintenance system 1 according to the embodiment is a maintenance system for returning an industrial robot that has finished maintenance work to a pre-work posture that is a posture before starting the maintenance work, and includes an acquisition unit that acquires a posture of the industrial robot, and a presentation unit that presents, to a worker, the pre-work posture indicating the posture of the industrial robot acquired by the acquisition unit before starting the maintenance work.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an industrial robot maintenance system for maintaining an industrial robot. [Background technology]

[0002] Conventionally, it has been proposed to use mixed reality technology to perform simulations when installing a robot, for example (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-8473 Summary of the Invention [Problem to be solved by the invention]

[0004] However, when maintenance work is actually performed on an industrial robot, it is required to return the industrial robot to the posture it had before the maintenance work began (hereinafter referred to as the "pre-work posture"). This is because industrial robots are set to start operating from a predetermined posture (hereinafter referred to as the "home position"), and if the posture is different from the home position, there is a risk that the robot will not be able to start operating.

[0005] However, if the worker forgets the pre-work posture, there is a risk that the industrial robot will not be able to return to the pre-work posture. Also, for example, if multiple fixed positions are set, there is a risk that the worker will not be able to determine which fixed position the pre-work posture is, and will not be able to return the industrial robot to the pre-work posture.

[0006] The present invention has been made in consideration of the above-described circumstances, and an object of the present invention is to provide a maintenance system for an industrial robot that can return an industrial robot that has completed maintenance work to the posture it had before the maintenance work began. [Means for solving the problem]

[0007] In the invention described in claim 1, the maintenance system for an industrial robot is a maintenance system for returning an industrial robot that has completed maintenance work to a pre-work posture, which is the posture before the maintenance work began, and includes an acquisition unit that acquires the posture of the industrial robot, and a presentation unit that presents to a worker the pre-work posture, which indicates the posture of the industrial robot acquired by the acquisition unit before the maintenance work began.

[0008] In this way, by configuring the industrial robot so that its posture can be acquired, the industrial robot's posture can be acquired before starting maintenance work, preventing the worker from forgetting its pre-work posture and being unable to return it to the posture before starting maintenance work. Furthermore, by making it possible to present the acquired pre-work posture to the worker, the worker can compare the industrial robot's posture after maintenance work with the posture acquired before starting maintenance work. Then, if the current posture of the industrial robot matches the pre-work posture, it can be determined that the industrial robot's posture has returned to the state it was in before starting maintenance work. Therefore, the industrial robot can be returned to its pre-work posture.

[0009] According to the invention described in claim 2, a management unit for managing work procedures is provided, and the management unit manages the work of acquiring the pre-work posture of the industrial robot and the work of returning the industrial robot to the pre-work posture after maintenance work is completed in addition to the work procedures. This makes it possible to prevent forgetting to acquire the pre-work posture and being unable to return the industrial robot to the pre-work posture, and to prevent forgetting to return the industrial robot to the pre-work posture after maintenance work.

[0010] According to the invention described in claim 3, the management unit manages the work procedures by adding to them a task of requesting a third party other than the operator to confirm that the task of returning the industrial robot to the pre-work posture has been completed. This makes it possible to confirm by a so-called double check whether the industrial robot has been returned to the pre-work posture, and more reliably prevents forgetting to return the industrial robot to the pre-work posture after maintenance work.

[0011] According to the invention described in claim 4, the acquisition unit acquires the pre-work posture by capturing an image of the industrial robot with the imaging unit before starting maintenance work. This makes it possible to easily acquire the pre-work posture without placing an excessive burden on the worker. Furthermore, since an excessive burden is not placed on the worker, there is no decrease in work efficiency.

[0012] According to the invention described in claim 5, the presenting unit presents the pre-work posture by displaying on the display unit an image of the industrial robot captured by the imaging unit before starting maintenance work. This makes it possible to present the pre-work posture easily and in a manner that is easy for the worker to confirm.

[0013] According to the invention described in claim 6, the acquisition unit acquires data indicating the posture of the industrial robot from the control device of the industrial robot or an operating device connected to the control device. This makes it possible to acquire the pre-work posture even in a workplace where, for example, image capture is prohibited. However, if the workplace is not prohibited from image capture, it is possible to acquire the pre-work posture as an image by capturing an image with the image capture unit, and then further acquire data indicating the pre-work posture, such as the rotation angle of each axis.

[0014] According to the invention recited in claim 7, the industrial robot includes an image generation unit that generates a model image of the industrial robot based on the acquired posture of the industrial robot, and the presentation unit presents the pre-work posture by displaying the model image generated based on the acquired data indicating the pre-work posture on the display unit. This makes it possible to present an image indicating the pre-work posture even in, for example, a work site where imaging by the imaging unit is prohibited, and by comparing the model image with the current posture of the industrial robot, it is possible to easily check whether the industrial robot has returned to the pre-work posture.

[0015] According to the invention of claim 8, a type identification unit is provided that identifies the type of industrial robot, and the image generation unit generates a model image corresponding to the identified type. This makes it possible to present a virtual model image corresponding to the actual industrial robot, making it easier to compare with the actual industrial robot, and therefore making it possible to more accurately confirm whether the industrial robot has been able to return to its pre-work posture.

[0016] According to the invention described in claim 9, an orientation identification unit is provided that identifies the orientation relative to the industrial robot, and the image generation unit generates a model image according to the orientation relative to the industrial robot. This makes it possible to generate a model image that corresponds to the position and viewpoint of the worker, making it easy to check whether the worker has been able to return to the pre-work posture. In addition, it becomes possible to check whether the posture matches from different viewpoints, making it possible to more accurately check whether the worker has been able to return to the pre-work posture.

[0017] According to the invention described in claim 10, the presenting unit presents the pre-work posture in accordance with the actual size of the industrial robot imaged by the imaging unit and displayed on the display unit, thereby making it easy to confirm whether or not the industrial robot has been returned to the pre-work posture.

[0018] According to the invention described in claim 11, the presentation unit presents at least one of the images of the industrial robot captured by the imaging unit in the pre-work posture or after the maintenance work is completed in a manner that allows the image to be distinguished from the other image. This makes it easier to compare the current posture of the industrial robot with the pre-work posture, and to easily confirm whether the industrial robot has been able to return to the pre-work posture. In this case, the two images can be presented in a distinguishable manner by displaying one of the images as a wireframe image, by changing the display color or line type, or by changing the transparency.

[0019] According to the invention described in claim 12, the presentation unit presents the difference between the pre-work posture and the posture of the industrial robot after the maintenance work is completed. This makes it possible to grasp the difference in posture numerically in addition to comparing the postures using images, for example, and more reliably confirm whether the industrial robot has been able to return to the pre-work posture.

[0020] According to the invention described in claim 13, the presenting unit presents the pre-work posture by displaying it on a mobile terminal carried by the worker or on a display unit provided in a wearable display device worn by the worker. This reduces the risk that presenting the pre-work posture will be a burden on the worker, and also allows the worker to easily check the pre-work posture, thereby improving work efficiency. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 is a diagram illustrating a configuration example of a maintenance system according to an embodiment. [Figure 2] FIG. 1 is a diagram illustrating a configuration example of an operating device. [Figure 3] FIG. 1 is a diagram illustrating an example of the electrical configuration of a worker terminal; [Figure 4] FIG. 1 is a diagram showing an example of a home position set in an industrial robot and an example of a program set in an operating device for returning the robot to the home position; [Figure 5] A diagram showing the processing flow of the maintenance system [Figure 6] A diagram showing an example of the display on a worker's terminal before and after starting maintenance work. [Figure 7] FIG. 10 is a diagram schematically illustrating a process from obtaining a pre-work posture to returning to the pre-work posture. [Figure 8] Schematic diagram of another method for acquiring pre-task posture [Figure 9] Schematic diagram 1 showing another method for checking return to pre-work posture [Figure 10] Diagram 2 showing another method for checking return to pre-work posture [Figure 11] Diagram 3 showing another method for checking return to pre-work posture [Figure 12] Schematic diagram of another method for returning to the pre-work posture [Figure 13] FIG. 10 is a diagram schematically illustrating another method and display mode for presenting a pre-work posture. DETAILED DESCRIPTION OF THE INVENTION

[0022] Hereinafter, embodiments will be described with reference to the drawings. FIG. 1 shows an example of the configuration of a maintenance system 1 for an industrial robot according to this embodiment. The robot 2 shown as an example of an industrial robot is a so-called six-axis robot with vertical articulated joints. However, the industrial robot may also be a so-called seven-axis robot with vertical articulated joints or a so-called four-axis robot with horizontal articulated joints. In other words, the maintenance system 1 can be used for industrial robots such as six-axis and seven-axis robots whose posture changes when the arms rotate, and four-axis robots whose posture changes when the arms rotate or a linear shaft moves up and down.

[0023] The robot 2 has a base placed on an installation surface, a shoulder rotatable relative to the base, a lower arm rotatable relative to the shoulder, a first upper arm rotatable relative to the lower arm, a second upper arm coaxially rotatable relative to the first upper arm, and a wrist attached to the tip of the second upper arm. A hand or tool (not shown) is attached to a flange attached to the tip of the wrist of the robot 2, and the robot 2 repeatedly executes taught operations.

[0024] The robot 2 is provided with an identifier 2a, such as a two-dimensional code, that indicates the type and model of the robot 2, in a position visible to the worker (H1). The robot 2 is fixed to the installation surface by a predetermined number of anchors, for example, three anchors 23A, 23B, and 23C, that are arranged in predetermined positions on the base. The positions of these anchors 23 and the spacing between the anchors 23 are determined depending on the type of robot 2. In other words, each anchor 23 corresponds to an identification structure that can identify the shape of the robot 2 based on its orientation, position, or type.

[0025] The control device 3 is connected to the robot 2 and controls the operation of the robot 2. The control device 3 is also connectable to an operation device 4 operated by a worker, and accepts operations input to the operation device 4 and controls the robot 2 in accordance with the input operations, thereby enabling, for example, teaching work of the robot 2.

[0026] In this embodiment, the operation device 4 is assumed to be a teaching device that teaches the robot 2. As shown in Fig. 2, the operation device 4 is configured with, for example, a liquid crystal panel or an organic EL panel, and is provided with an operation display unit 4a that displays information such as a user interface when operating the robot 2 and the rotation angle of each axis. The operation device 4 also has an operation input unit 4b that is configured with an enable switch, a deadman switch, buttons, switches, or a touch panel provided corresponding to the operation display unit 4a.

[0027] The operation device 4 displays, for example, a two-dimensional code (M1) or model number (M2) indicating the type and model of the robot 2, angle information (M3) indicating the current rotation angle of each axis of the robot 2, and a virtual image (M4) of the robot 2 on the operation display unit 4a. However, the configuration of the operation device 4 and the information displayed thereon shown in Fig. 2 are merely examples. The operation device 4 can be configured to run operation software on, for example, a laptop computer, smartphone, or tablet computer, as long as it is communicably connected to the control device 3 and can operate the robot 2.

[0028] 1, the operation device 4 is communicably connected to an operator terminal 5 carried by an operator (A1) performing maintenance work via a wired or wireless communication path. The operator terminal 5 is communicably connected to an administrator terminal 7 carried by an administrator (H2) and a management device 8 via a network 6. In this embodiment, a so-called smartphone is assumed as the operator terminal 5, but any device that can be carried by the operator, such as a tablet PC, may be used.

[0029] 3, the worker terminal 5 includes a control unit 10, a memory unit 11, an imaging unit 12, a display unit 13, a speaker 14, a microphone 15, an input unit 16, a communication unit 17, a position sensor 18, and an acceleration sensor 19. The control unit 10 includes a CPU, a ROM, a RAM, and the like (not shown), and controls the entire worker terminal 5 by executing a program stored in the memory unit 11.

[0030] The storage unit 11 is configured, for example, with a semiconductor memory, and stores programs executed by the control unit 10 and various data. The storage unit 11 also stores the type of robot 2, shape data of the robot 2 corresponding to the type, various application programs required for maintenance work, etc. The shape data of the robot 2 can be configured to be downloaded each time from the operation device 4 or the management device 8, or shape data of a robot 2 of a type that is not stored can be newly downloaded.

[0031] The imaging unit 12 is composed of, for example, a CMOS camera or a CCD camera, and captures images of the robot 2 and the screen of the operating device 4, as will be described later. The display unit 13 is composed of, for example, a liquid crystal panel or an organic EL panel, and displays various information necessary for maintenance work, such as the pre-work posture, which will be described later, based on video signals output from the control unit 10. The input unit 16 is composed of, for example, a touch panel provided corresponding to the display unit 13, and receives inputs from the operator.

[0032] The speaker 14 outputs sound corresponding to an audio signal output from the control unit 10. The microphone 15 inputs the voice of the worker and outputs it as an audio signal to the control unit 10. The communication unit 17 communicates between the operation device 4 and the network 6. Note that while FIG. 3 illustrates a configuration in which one communication unit 17 is provided, if the communication methods used by the operation device 4 and the network 6 are different, it is also possible to provide communication units 17 compatible with multiple communication methods, or to provide multiple communication units 17 for each communication method.

[0033] Position sensor 18 is configured, for example, by a GPS device, and detects the position of worker terminal 5 in a real three-dimensional coordinate system. Acceleration sensor 19 is configured, for example, by a sensor that detects acceleration in three axes directions, and detects the inclination of worker terminal 5 and its orientation relative to robot 2 based on the acceleration in the three axes directions applied to worker terminal 5. Note that the configuration of worker terminal 5 shown in FIG. 3 is just an example, and worker terminal 5 may have other functions.

[0034] The worker terminal 5 also includes functional units, such as an acquisition unit 10a, a presentation unit 10b, a management unit 10c, an image generation unit 10d, a type identification unit 10e, and an orientation identification unit 10f. In this embodiment, these functional units are realized by software by executing a program in the control unit 10.

[0035] The acquisition unit 10a is a functional unit that executes a process for acquiring the posture of the robot 2. As will be described in detail later, the acquisition unit 10a acquires the posture of the robot 2 by capturing images of the robot 2 and the screen of the operation device 4 using the imaging unit 12, and by acquiring data indicating the current rotation angles of each axis of the robot 2 from the operation device 4 via the communication unit 17. Hereinafter, the posture of the robot 2 acquired before starting maintenance work will be referred to as the pre-work posture. This pre-work posture is acquired as an image or data depending on the acquisition mode, as will be described later. Alternatively, the pre-work posture can be acquired from the control device 3 instead of the operation device 4.

[0036] The presentation unit 10b is a functional unit that executes a process of presenting the pre-work posture acquired by the acquisition unit 10a to the worker before starting maintenance work. As will be described in detail later, the presentation unit 10b presents the pre-work posture to the worker by displaying an image or data showing the pre-work posture on the display unit 13. At this time, the pre-work posture is presented as an image or data depending on the acquisition mode, as will be described later. The presentation unit 10b can also present the pre-work posture by displaying a model image, which will be described later, on the display unit 13.

[0037] The management unit 10c is a functional unit that executes a process for managing work procedures when performing maintenance work. As will be described in detail later, the management unit 10c manages, in addition to the work procedures, the work of acquiring the pre-work posture of the robot 2 and the work of returning the robot 2 to the pre-work posture after the maintenance work is completed. In this case, it is assumed that the work procedures are created as electronic media that can be displayed on the worker terminal 5, but it is also possible to use so-called procedure manuals created on paper media that have been imported and made displayable on the worker terminal 5. Furthermore, as will be described in detail later, the management unit 10c also manages, in addition to the work procedures, the work of requesting a third party other than the worker, such as a manager, to confirm whether the work of returning the robot 2 to the pre-work posture has been performed.

[0038] The image generation unit 10d is a functional unit that executes processing to generate a model image of the robot 2 based on the acquired posture of the robot 2. For example, the image generation unit 10d generates a model image in which the robot 2 in the same posture is modeled in a virtual space based on the pre-task posture acquired as data indicating the rotation angles of each axis. The image generation unit 10d can also generate a model image by performing image processing on an image captured by the imaging unit 12. The image generation unit 10d can also generate, for example, a wireframe image in which the outline is extracted, or an image captured by the imaging unit 12 and displayed on the display unit 13 in a different display color, line type, or transparency from the actual robot 2, by performing image processing on the generated model image or the image captured by the imaging unit 12.

[0039] The type identification unit 10e is a functional unit that executes processing to identify the type of the robot 2. In this case, the type is identified by reading the identifier 2a provided on the robot 2 with the imaging unit 12, or by reading the identification information displayed on the operation device 4 with the imaging unit 12, or by the worker inputting the information into the worker terminal 5. The type of the robot 2 is also information that can identify the shape of the robot 2. As described above, the memory unit 11 stores shape data according to the type of the robot 2. Therefore, the image generation unit 10d can generate a model image based on the identified type of the robot 2.

[0040] The orientation identification unit 10f is a functional unit that executes processing to identify the orientation of the worker relative to the robot 2, or more strictly, the orientation of the worker terminal 5 relative to the robot 2. At this time, the orientation identification unit 10f identifies the orientation relative to the robot 2 based on the tilt and orientation of the worker terminal 5 detected by the acceleration sensor 19, the current position of the worker terminal 5 detected by the position sensor 18, and the like. In other words, the orientation identification unit 10f identifies the positional relationship between the robot 2 and the worker terminal 5, including the orientation of the worker terminal 5.

[0041] However, the orientation identification unit 10f can also identify the orientation and position of the worker terminal 5 relative to the robot 2 based on the type of robot 2 and the size and orientation of the robot 2 in the image captured by the imaging unit 12. In this case, the image generation unit 10d can generate a model image according to the orientation and position of the worker terminal 5, that is, a model image according to the worker's viewpoint, based on the identified orientation.

[0042] In this embodiment, the administrator terminal 7 is assumed to be a smartphone, and is configured to be able to communicate with the worker terminal 5 via the network 6 and to be able to execute approval tasks, which will be described later. However, the administrator terminal 7 can also be, for example, a laptop computer, tablet computer, or desktop computer. This administrator terminal 7 performs so-called event-driven processing, in which it receives a notification from the worker terminal 5 and executes the corresponding process.

[0043] In this embodiment, the management device 8 is assumed to be a so-called server device or the like, and is configured to be able to communicate with the worker terminal 5 via the network 6 and to be able to execute approval tasks, which will be described later. However, in this embodiment, it is sufficient that the maintenance system 1 is provided with either the administrator terminal 7 or the management device 8. Of course, it is also possible to configure the maintenance system 1 to have both.

[0044] Next, the operation of the maintenance system 1 will be described. As described above, when maintenance work is performed on the robot 2, it is necessary to return the robot 2 to the pre-work posture when the maintenance work is completed. At this time, as shown as a list of fixed positions in Fig. 4, for example, the robot 2 may be set with multiple fixed positions (A), (B), and (C) to accommodate different tasks.

[0045] When multiple home positions are set in this way, the robot 2 can be returned to the corresponding home position by selecting and executing a program displayed in a list on the operation display unit 4a of the operation device 4, as shown in the program list. For example, executing home_position_A can return the robot 2 to home position (A). Executing home_position_B can return the robot 2 to home position (B), and executing home_position_C can return the robot 2 to home position (C). Note that take_out, hand_open1, and hand_close1 are programs for causing the robot 2 to perform other actions. However, the home positions and programs shown in FIG. 4 are merely examples.

[0046] However, if the worker forgets the pre-work posture, there is a risk that the robot 2 will not be able to be returned to the pre-work posture even if a program for returning it to its home position is registered in the operation device 4. Furthermore, when maintenance work is completed, it is generally required to return the robot 2 to its pre-work state, and in such cases, it is expected that the pre-work posture will not necessarily be the home position. Therefore, even if only one home position is registered in the operation device 4, there is a risk that the robot 2 will not be able to be returned to its pre-work state if that home position is different from the pre-work posture.

[0047] Therefore, the maintenance system 1 is configured to reliably return the posture of the robot 2 that has performed maintenance work to the pre-work posture, i.e., the posture before the maintenance work began, as follows. Note that, as described above, there are multiple conceivable methods for acquiring the pre-work posture and for presenting the pre-work posture, and therefore, below, an example configuration of the maintenance system 1 will be described as an example configuration together with the processing flow, and then other methods will be described as modified examples.

[0048] (Configuration example) 5 shows the processing flow of the worker terminal 5 when performing maintenance work and the processing flow of the manager terminal 7. At this time, the processing is performed by the above-mentioned functional units in the worker terminal 5, but for simplicity of explanation, the following explanation will be centered on the worker terminal 5. Also, in this embodiment, an example is shown in which the worker terminal 5 and the manager terminal 7 work together, but a configuration in which the management device 8 and the worker terminal 5 work together instead of the manager terminal 7 is also possible. Note that the manager terminal 7 or the management device 8 executes processing upon receiving a notification from the worker terminal 5, and therefore is shown in the form of a sequence diagram.

[0049] When the worker terminal 5 is activated by the worker and starts processing, it adds a work procedure to the procedure manual (S1). When performing maintenance work, it is considered that a procedure manual is created that describes the flow of work to be performed, such as Task 1 (P1), Task 2 (P2), and Task 3 (P3), as shown as an example in FIG. 6. In this embodiment, the procedure manual is assumed to be a so-called standard operating procedure manual that defines predetermined work procedures for performing periodic maintenance, for example. However, it may also be a procedure manual created each time a repair is performed, for example. Note that the procedure manual shown in FIG. 6 is just an example. Also, the network 6 is not shown in FIG. 6.

[0050] The worker terminal 5 then adds to the procedure manual, as tasks to be performed before starting maintenance work, a task for acquiring the pre-work posture (P10) and a task for receiving a confirmation notification (P11) for obtaining confirmation that the pre-work posture has been obtained, and adds, as tasks to be performed when completing maintenance work, a task for returning to the pre-work posture (P12), a task for confirming posture (P13) that the worker confirms that the posture matches the pre-work posture, a request for approval (P14) for obtaining approval from the manager for returning to the pre-work posture, and a request for approval (P15) for the worker to confirm that approval from the manager has been obtained. The process of adding each task is mainly performed by the management unit 10c.

[0051] In this embodiment, the names of each task displayed on the worker terminal 5 are displayed in a display area that supports touch operations. Therefore, for example, when the worker touches the display area within the frame line for posture acquisition, a process for acquiring the posture is executed, as described below. In other words, the worker terminal 5 presents the tasks to be performed in a state that the worker can see and in the order in which they should be performed. This prevents the worker from forgetting or skipping a task. Furthermore, since the corresponding process can be executed by touching the task name, the corresponding task can be easily performed without making any mistakes in the work procedure.

[0052] When the worker touches the posture acquisition button shown in FIG. 5, the worker terminal 5 executes a posture acquisition process for acquiring the pre-work posture (S1). In this posture acquisition process, as shown in FIG. 7 as a posture acquisition mode, for example, the worker captures an image of the current posture of the robot 2 using the imaging unit 12 of the worker terminal 5, thereby acquiring the posture of the robot 2 before starting maintenance work as the pre-work posture. Hereinafter, the image acquired as the pre-work posture will be referred to as the reference image 20 for convenience. Note that the acquisition mode shown in FIG. 7 is an example, and the pre-work posture can also be acquired in other acquisition modes as described below. This process is mainly performed by the acquisition unit 10a.

[0053] When the pre-work posture of the robot 2 is imaged and acquisition of the pre-work posture is completed, the worker terminal 5 transmits a notification of the posture acquisition to the manager terminal 7 (S2). This notification of posture acquisition is transmitted so that the manager terminal 7 can also confirm that the pre-work posture has been acquired, as will be described below. When the manager terminal 7 receives the posture acquisition, it displays a message (M10) indicating that the posture acquisition has been received and a confirmation button (M11) for inputting confirmation, as shown in FIG. 6, and when the manager touches the confirmation button, it transmits a confirmation notification to the worker terminal 5 (T1), as shown in FIG. 4. This allows both the worker and the manager to double-check that the worker has acquired the pre-work posture, that is, that preparations are complete to return the robot to the pre-work posture after maintenance work.

[0054] It should be noted that the system may be configured to send a notification to the administrator terminal 7 that work will begin when the posture acquisition process is executed. In this case, for example, if a posture acquisition notification is not received within a predetermined time after the work start notification is received, the system can prevent forgetting to acquire the pre-work posture by checking with the worker terminal 5 whether or not the pre-work posture has been acquired. Furthermore, if the confirmation is made by the management device 8 instead of the administrator terminal 7, the confirmation can be made automatically without going through the administrator.

[0055] Now, when the worker terminal 5 transmits the posture acquisition notification, it determines whether or not a confirmation notification has been received from the manager terminal 7 (S3), and if not received (S3: NO), it waits (S3: NO), but if received (S3: YES), it executes maintenance work processing (S4). This maintenance work processing is processing corresponding to work 1, work 2, and work 3 shown in FIG. 6.

[0056] For example, when a worker performs a task corresponding to task 1 and touches the display area for task 1 upon completion of the task, the worker terminal 5 manages the work procedure by performing a process such as graying out the task as the task is completed, thereby preventing the worker from skipping a necessary task.

[0057] 7 as a post-work state, when the worker has performed the required work, it is assumed that the pre-work posture of the robot 2, indicated by the dashed line, will be different from the posture of the robot 2 after the work. In this case, as described above, it is necessary to return the robot 2 to the pre-work posture, and it is also necessary to check whether the robot 2 after the return matches the pre-work posture.

[0058] Therefore, the worker terminal 5 executes the return process shown in Fig. 4 (S5). Specifically, when the worker touches the display area for returning the posture shown in Fig. 6, a reference image 20, which is an image of the posture before the work, and a return confirmation button 21 are displayed on the display unit 13 of the worker terminal 5. Then, the worker changes the posture of the robot 2 by selecting and executing a program set in the operation device 4 for returning the robot 2 to its home position.

[0059] 7 as a return confirmation mode, the worker visually checks whether the current posture of the robot 2 matches the pre-work posture by comparing it with the reference image 20 displayed on the worker terminal 5. If it is determined that the two postures match, the worker touches the return confirmation button 21 to confirm that the robot has returned to the pre-work posture and terminates the return process in step S5. If it is determined that the two postures do not match, the worker executes a program corresponding to another fixed position to change the posture of the robot 2 and reconfirms whether the robot has returned to the pre-work posture.

[0060] As shown in Fig. 4, when the return process is completed after the return of the worker to the pre-work posture is confirmed, the worker terminal 5 transmits an approval request to the manager terminal 7 (S6). Specifically, when the display area for the approval request shown in Fig. 6 is touched, the worker terminal 5 transmits the approval request to the manager terminal 7. Then, the worker terminal 5 waits for an approval notification from the manager terminal 7 (S6: NO).

[0061] When the manager terminal 7 receives the approval request, it displays a message (M20) indicating that the approval request has been received and an approve button (M21), as shown in Fig. 6. Then, when the manager touches the approve button, the manager terminal 7 transmits an approval notification to the worker terminal 5 (T2). On the other hand, when the worker terminal 5 receives the approval notification (S6: YES), it concludes that the manager's approval has been obtained and ends the process.

[0062] In this way, the maintenance system 1 can reliably return the robot 2 to its pre-work posture after the maintenance work is completed. When the worker terminal 5 receives the approval notification, it can notify the worker that approval has been obtained by outputting a sound from the speaker 14 or by changing the display mode on the display unit 13, for example, by graying out the "received approval" message shown in Fig. 6. In other words, the display unit 13 and the speaker 14 can also function as part of the presentation unit 10b that presents the notification to the worker, and as part of the management unit 10c that manages the work procedures.

[0063] (Variation) Below are described other methods for acquiring the pre-work posture, other methods for checking the pre-work posture, other methods for returning to the pre-work posture, and other methods for presenting the pre-work posture for constructing the maintenance system 1. Furthermore, each of the methods described below can be substituted for or shared with the methods described in the above configuration examples.

[0064] 8 as another acquisition method 1, the maintenance system 1 can acquire the pre-work posture of the robot 2 as data on the rotation angle of each axis. For example, by capturing an image of a predetermined range (R1) displaying the current rotation angle of each axis of the robot 2 with the imaging unit 12, posture information that can identify the posture of the robot 2 before starting maintenance work can be acquired as the pre-work posture.

[0065] Alternatively, as shown as another acquisition method 2, the operation device 4 and the worker terminal 5 can be communicatively connected, and posture information capable of identifying the posture of the robot 2 before the start of maintenance work can be acquired as the pre-work posture. Furthermore, as shown as another acquisition method 3, the operation device 4 and the worker terminal 5 can be communicatively connected to acquire posture information, and a model image that matches the current posture of the robot 2 based on the acquired posture information can be generated in a virtual space, and the generated model image can be treated as a reference image 20 corresponding to the pre-work posture, thereby acquiring the pre-work posture. Note that it is also possible to acquire image data of an imageable image (M4) generated by the operation device 4, and use the acquired image data as the reference image 20 to determine the pre-work posture.

[0066] With this configuration, it is possible to acquire the pre-work posture for returning the robot 2 to the pre-work state. Furthermore, by acquiring posture information through communication, it is possible to acquire the pre-work posture even at a site where image capture by the image capture unit 12 is not permitted.

[0067] As shown in Figure 9 as another confirmation method 1, when checking whether the robot has returned to its pre-work posture, the maintenance system 1 can be configured to superimpose the reference image 20 and the current image of the robot 2 captured by the imaging unit 12, shown hatched, as shown as an example of superimposed display.

[0068] This makes it easier to compare the two images, and since it is considered that the robot 2 has returned to the pre-work posture when the two images are nearly overlapping, it is possible to easily and accurately confirm whether or not the robot 2 has been returned to the pre-work posture. Note that the other confirmation method 1 described here, and the other confirmation methods 2 and 3 described below can also be considered other presentation methods for presenting the pre-work posture.

[0069] In this case, by performing a process of adjusting the size of each image, it is possible to more accurately confirm that the robot 2 has returned to the pre-work posture. Specifically, a predetermined number of anchors 23 for installing the robot 2 on the installation surface are provided at predetermined positions for each type of robot 2. For example, as shown in Fig. 1, in the case of robot 2, anchors 23A, 23B, and 23C are provided at three locations on the bottom end of the base as identification structures that can identify the orientation and position of the robot 2 from the worker's viewpoint, the shape of the robot 2, etc.

[0070] As an example of size adjustment, assume that the distance between anchor 23A and anchor 23B is width (W1) in reference image 20 captured from the side of robot 2, and the distance between anchor 23A and anchor 23B is width (W2) in the current robot 2 captured by imaging unit 12. Note that width (W1) and width (W2) can be simply substituted with the number of pixels in the image.

[0071] In this case, the worker terminal 5 can enlarge or reduce the image of the pre-work posture according to the width ratio (= W2 / W1) to display each image with roughly the same size, as shown in the example of superimposed display, making it easier to determine whether or not it matches the image of the pre-work posture.

[0072] Furthermore, the worker terminal 5 can make it easier to distinguish between the reference image 20 and the current image of the robot 2 by superimposing and displaying them in different display colors, different line types, or different transmittances. For example, by displaying the reference image 20 as a so-called wireframe image in which the outline is extracted, it is possible to make it easier to distinguish between the reference image 20 and the current image of the robot 2. Furthermore, by setting the display color of the reference image 20 to a color different from the color of the robot 2, it is possible to make it even easier to distinguish between the image of the pre-work posture and the current image of the robot 2.

[0073] Furthermore, for example, by increasing the transparency of the reference image 20, it becomes easier to compare the reference image 20 with the current image of the robot 2 when they are superimposed. Furthermore, by processing at least one of the reference image 20 and the current image of the robot 2, and more preferably both, into an image in which objects other than the robot 2 are cut out, it becomes easier to determine whether or not the image matches the reference image 20. Hereinafter, captured objects other than the robot 2 will also be referred to as the background.

[0074] 10 shows an example of superimposed display in another confirmation method 2, the pre-work posture of the robot 2 can be presented by generating a three-dimensional model image in a virtual space and superimposing the generated model image on the current image of the robot 2. This model image is generated by the image generation unit 10d.

[0075] Specifically, when the rotation angles of each axis are acquired as images as described above, a model image can be generated by the operator inputting the acquired rotation angles of each axis. Alternatively, when the rotation angles of each axis are acquired as data, a model image can be generated by using the acquired data. When generating a model image, a model image according to the type of robot 2 can be generated by identifying the type of target robot 2. The process of identifying the type is mainly performed by the type identification unit 10e.

[0076] At this time, the orientation and position of the model image generated in the virtual space can be changed according to the field of view of the worker. For example, as shown in the example of superimposed display, if the orientation of the model image generated as the pre-work posture and the image of the actual robot 2 differ, as shown in the example of size adjustment, the orientation and size of the model image in the pre-work posture can be adjusted based on the position of the anchor 23 described above for each image. The process of specifying the position and orientation is mainly performed by the orientation specifying unit 10f.

[0077] This allows a model image corresponding to the position of the worker, i.e., reference image 20, to be displayed, making it easy to confirm that the worker has returned to the pre-work posture. Also, the position and line of sight of the worker, or more precisely, the position and orientation of the worker terminal 5 in a three-dimensional coordinate system, can be detected using position sensor 18 and acceleration sensor 19, and a model image corresponding to the worker's position and line of sight in relation to the installation position of robot 2 can be generated and displayed in the virtual space.

[0078] Furthermore, in both cases where a model image adjusted based on the position of the anchor 23 is generated, and where a model image is generated based on the position of the worker terminal 5, by regenerating the model image in accordance with changes in the position of the worker terminal 5, it becomes possible to compare the reference image 20 for determining posture consistency with the current posture of the robot 2 from multiple viewpoints, and it becomes possible to more accurately confirm whether the robot has returned to its pre-work posture.

[0079] Furthermore, when generating a model image, it is possible to generate images that are easy to distinguish, such as an image with the background removed, the wireframe image described above, an image with different colors, an image with different line types, and an image with different transmittance, and when displayed as the reference image 20, it is easy to check whether the pre-work posture has been returned to.

[0080] As shown in FIG. 11 as another confirmation method 3, the post-return posture can be confirmed using multiple methods. For example, an image of the robot 2 is acquired as a reference image 20, and information on the rotation angle of each axis is acquired by image or communication. When the robot is returned to the pre-work posture, the reference image 20 can be visually confirmed, and pre-work angle information 22 indicating the rotation angle of each axis acquired before starting maintenance work and the rotation angle (M3) of each axis displayed on the operation device 4 at the time of return can be confirmed. It is also possible to compare a virtual image (M4) displayed on the operation device 4 with the reference image 20. By confirming the return to the pre-work posture based on multiple pieces of information in this way, the confirmation of return can be made more accurately.

[0081] In this case, when the operation device 4 and the worker terminal 5 are connected to each other so as to be able to communicate with each other, as shown as an example of difference information display, it is possible to present difference information 22a, which is the difference between the angle of each axis in the pre-task angle information 22 and the current rotation angle of each axis of the robot 2 acquired from the operation device 4. In Fig. 11, the differences are shown as ΔJ1, ΔJ2, ΔJ3, ΔJ4, ΔJ5, and ΔJ6. This makes it possible to grasp the difference in posture numerically in addition to comparing postures using images, and to more reliably confirm whether or not the robot 2 has been returned to the pre-task posture.

[0082] As shown in Fig. 12 as another return method 1, a configuration can be adopted in which information on the rotation angle of each axis indicating the pre-work posture is input to the operating device 4, thereby returning the robot 2 to the post-return posture. In this case, if information on the rotation angle of each axis as the pre-work posture is acquired as an image, the operator can return the robot 2 to the pre-work posture by manually inputting the rotation angle of each axis. Alternatively, if information on the rotation angle of each axis as the pre-work posture is acquired as data, the data can be sent to the operating device 4 to return the robot 2 to the pre-work posture.

[0083] After returning the robot 2 to its pre-work posture, it is possible to confirm whether or not the robot 2 has been able to be returned to its pre-work posture by visually comparing the current posture of the robot 2 with an image of the robot 2 in the pre-work posture, comparing the images by superimposing them as described above, comparing the current rotation angles of each axis displayed on the operating device 4 with the rotation angles of each axis obtained before the work, or comparing the virtual image (M4) displayed on the operating device 4 with the reference image 20.

[0084] As shown in Figure 13, presentation of the pre-work posture is not limited to display on the worker terminal 5, but can also be displayed, for example, on an eyeglass-type display 30 worn by the worker as shown in other presentation method 1, or on a goggle-type display 31 worn to cover the worker's field of vision as shown in other presentation method 2.

[0085] That is, the maintenance system 1 can be configured to display the reference image 20 and data on the projection surface of the eyeglass-type display 30 or goggle-type display 31 that overlaps the worker's field of view. That is, the eyeglass-type display 30 or goggle-type display 31 functions as part of the presentation unit 10b that presents the pre-work posture to the worker. In this case, the eyeglass-type display 30 or goggle-type display 31 can be configured to be provided with a projection device 32 equivalent to the display unit 13, a camera 33 equivalent to the imaging unit 12, and sensors 34 equivalent to the position sensor 18 or acceleration sensor 19.

[0086] Even with this configuration, as shown as an example of a presentation mode, it is possible to confirm whether or not the robot has been able to return to the pre-work posture by, for example, superimposing the reference image 20 on the current image of the robot 2. In this case, by adjusting the size and position of the image projected into the worker's field of view as described above, and by generating a modeled image in accordance with the worker's viewpoint and any changes thereto and displaying it as the reference image 20, it is possible to easily confirm whether or not the robot has been able to return to the pre-work posture.

[0087] The maintenance system 1 described above can provide the following effects. An industrial robot maintenance system 1 for performing maintenance on an industrial robot includes an acquisition unit 10a that acquires the posture of the robot 2 as an industrial robot, and a presentation unit 10b that presents to a worker a pre-work posture that indicates the posture of the industrial robot acquired by the acquisition unit 10a before starting maintenance work.

[0088] In this way, by acquiring the posture of the robot 2 before the start of maintenance work in advance, when the maintenance work is completed, it is possible to compare the current posture of the robot 2 with the posture of the robot 2 before the start of maintenance work. If the current posture of the robot 2 matches the posture of the robot 2 before the start of maintenance work, it can be confirmed that the posture of the robot 2 is the posture before the start of maintenance work. Therefore, the industrial robot can be returned to the pre-work posture.

[0089] The maintenance system 1 also includes a management unit 10c that manages work procedures, and the management unit 10c manages, in addition to the work procedures, the work of acquiring the pre-work posture of the industrial robot and the work of returning the industrial robot to the pre-work posture after the maintenance work is completed. This makes it possible to prevent the robot from forgetting to acquire the pre-work posture and being unable to return to the pre-work posture, or from forgetting to return to the pre-work posture after the maintenance work.

[0090] Furthermore, in the maintenance system 1, the management unit 10c manages, in addition to the work procedures, a task that requires a third party other than the worker to confirm that the task of returning the industrial robot to the pre-work posture has been completed. This makes it possible to double-check and confirm that the industrial robot has been returned to the pre-work posture after the maintenance work, and more reliably prevents forgetting to return the industrial robot to the pre-work posture after the maintenance work.

[0091] Furthermore, in the maintenance system 1, the acquisition unit 10a acquires the pre-work posture by capturing an image of the industrial robot with the imaging unit 12 before starting maintenance work. This makes it possible to easily acquire the pre-work posture. Furthermore, since this does not place an excessive burden on the worker, it does not result in a decrease in work efficiency.

[0092] Furthermore, in the maintenance system 1, the presentation unit 10b presents the pre-work posture by displaying an image of the industrial robot captured by the imaging unit 12 before starting maintenance work on the display unit 13. This makes it possible to easily present the pre-work posture.

[0093] Furthermore, in the maintenance system 1, the acquisition unit 10a acquires the pre-work posture by acquiring data indicating the posture of the industrial robot from the control device 3 of the industrial robot or the operation device 4 connected to the control device 3. This makes it possible to acquire the pre-work posture even in, for example, a work site where imaging by the imaging unit 12 is prohibited. In this case, after acquiring the pre-work posture as an image by capturing an image with the imaging unit 12, it is also possible to further acquire data indicating the pre-work posture, such as the rotation angle of each axis.

[0094] The maintenance system 1 also includes an image generation unit 10d that generates a model image of the industrial robot based on the acquired posture of the industrial robot, and the presentation unit 10b presents the pre-work posture by displaying the model image generated based on the acquired data indicating the pre-work posture on the display unit 13. This makes it possible to present an image indicating the pre-work posture even in, for example, a work site where imaging by the imaging unit 12 is prohibited, and by comparing the current posture of the industrial robot with the image of the pre-work posture, it is possible to easily confirm whether or not the industrial robot has been able to return to the pre-work posture.

[0095] The maintenance system 1 also includes a type identification unit 10e that identifies the type of industrial robot, and an image generation unit 10d that generates a model image corresponding to the identified type. This makes it possible to present a virtual image that matches the actual industrial robot, allowing for more accurate confirmation of whether the robot has been returned to its pre-work posture.

[0096] Furthermore, in the maintenance system 1, the presentation unit 10b presents the pre-work posture in accordance with the size of the actual industrial robot imaged by the imaging unit 12 and displayed on the display unit 13. This makes it easy to check whether the industrial robot has been able to return to the pre-work posture.

[0097] The maintenance system 1 also includes an orientation identification unit 10f that identifies the orientation relative to the industrial robot, and an image generation unit 10d that generates a model image according to the orientation relative to the industrial robot. This makes it possible to generate a model image that corresponds to the position and viewpoint of the worker, making it easy to check whether the worker has been able to return to the pre-work posture.

[0098] Furthermore, in the maintenance system 1, the presentation unit 10b presents the pre-work posture in accordance with the size of the actual industrial robot imaged by the imaging unit 12 and displayed on the display unit 13. This makes it possible to easily and reliably determine whether the posture of the actual industrial robot matches the pre-work posture.

[0099] Furthermore, in the maintenance system 1, the presentation unit 10b presents at least one of the images of the industrial robot captured by the imaging unit 12 in the pre-work posture or after the maintenance work has been completed in a manner that allows it to be distinguished from the other image. In this case, by displaying the reference image 20 as a wireframe image, or by displaying it in a different display color or line type, or by displaying it with a different transparency, it becomes easier to compare the current posture of the robot 2 with the pre-work posture, and it becomes easy to check whether or not the robot 2 has been able to return to the pre-work posture.

[0100] Furthermore, in the maintenance system 1, the presentation unit 10b presents the difference between the posture before the work and the posture of the industrial robot after the maintenance work is completed. This makes it possible to grasp the difference in posture numerically, for example, in addition to comparing the postures using an image, and more reliably confirm whether the robot 2 has been able to return to the posture before the work.

[0101] Furthermore, in the maintenance system 1, the presenting unit 10b presents the pre-work posture by displaying it on a mobile terminal carried by the worker or a display unit 13 provided on a wearable display device worn by the worker. This allows the worker to easily check the pre-work posture, thereby improving work efficiency.

[0102] The present invention is not limited to the embodiments described above or shown in the drawings, and various modifications, extensions, or combinations with other configurations within the scope of the gist thereof are included in the scope of equivalents, as described below.

[0103] In the embodiment, the maintenance system 1 is exemplified as being configured to communicate via the network 6. However, a configuration in which communication is via the network 6 is not essential, and a maintenance system 1 that is complete with the worker terminal 5 can be constructed. That is, a maintenance system 1 can also be constructed that does not include the network 6, the manager terminal 7, or the management device 8. In this case, the worker terminal 5 can be configured to be able to confirm that the pre-work posture has been acquired and that the robot has returned to the pre-work posture. This configuration can also prevent the industrial robot from forgetting to acquire the pre-work posture or forgetting to return to the pre-work posture, and return the industrial robot to the pre-work posture. In this case, the work history on the worker terminal 5 can be shown to the manager for confirmation or approval.

[0104] In the embodiment, the configuration has been exemplified in which the acquisition of the pre-work posture and the return to the pre-work posture are confirmed or approved by the manager or the management device 8, but a configuration in which either the acquisition of the pre-work posture or the return to the pre-work posture is confirmed or approved may also be used. Also, a configuration in which the acquisition of the pre-work posture and the return to the pre-work posture are recorded as work history in the worker terminal 5 or the management device 8 without confirmation or approval being performed by the manager terminal 7 or the management device 8 may also be used. Also, for example, a configuration in which the acquisition of the pre-work posture is confirmed by the management device 8 and the return to the pre-work posture is approved by the manager terminal 7 may also be used.

[0105] In the embodiment, an example of a configuration in which work procedures are also managed in conjunction with an electronic procedure manual has been shown, but it is also possible to configure the application program for managing the work procedures to be executed separately, separating the procedure manual from the management of the work. This makes it possible to deal with cases where work procedures are not necessarily fixed, such as repairing a malfunction, rather than where routine maintenance is not performed. In this case, although the embodiment shows an example in which an application program for performing work is linked so that it can be called from the procedure manual, it is also possible to configure the application program to be executed separately from the procedure manual. Of course, it is also possible to configure the application program to be partially linked.

[0106] In the embodiment, a configuration has been exemplified in which the administrator or the management device 8 can confirm whether or not the pre-work posture has been acquired by respectively notifying the start of work and the acquisition of the pre-work posture, but this can be simplified. For example, a configuration can be adopted in which the administrator is notified of the acquisition of the pre-work posture without notifying the start of work. Furthermore, a configuration can be further simplified in which the administrator requests approval for the work in which the user has returned to the pre-work posture without notifying the start of work and the acquisition of the pre-work posture.

[0107] In addition, it is also possible to construct a maintenance system 1 in which communication with the administrator terminal 7 or the management device 8 is not performed, but rather the worker terminal 5 is configured to check whether the worker has returned to the pre-work posture, in other words, the worker terminal 5 is configured to check whether the worker has returned to the pre-work posture.

[0108] In the embodiment, an example of a configuration in which each functional unit is provided in a mobile terminal is shown, but it is also possible to provide some of the functional units provided in the mobile terminal in the control device 3, the operation device 4, or the management device 8 connected to the network 6, so that the functions of the maintenance system 1 are shared among multiple devices.

[0109] For example, it is possible to configure the server device to execute high-load processing, or to provide the management unit 10c in the server device to centrally manage work procedures. Also, it is possible to implement each functional unit of the worker terminal 5 exemplified in the embodiment in the operation device 4, and to construct a maintenance system 1 that is completed by the operation device 4, or a maintenance system 1 in which the operation device 4 is communicably connected to the administrator terminal 7 or the management device 8. [Explanation of symbols]

[0110] In the drawings, 1 indicates a maintenance system, 2 indicates a robot (industrial robot), 3 indicates a control device, 4 indicates an operating device, 5 indicates a worker terminal, 7 indicates a manager terminal, 8 indicates a management device, 10a indicates an acquisition unit, 10b indicates a presentation unit, 10c indicates a management unit, 10d indicates an image generation unit, 10e indicates a type identification unit, 10f indicates an orientation identification unit, 12 indicates an imaging unit, 13 indicates a display unit, 14 indicates a speaker (presentation unit), 18 indicates a position sensor, 19 indicates an acceleration sensor, 20 indicates a reference image (image showing the posture before work), 30 indicates an eyeglass-type display (presentation unit, display unit), and 31 indicates a goggle-type display (presentation unit, display unit).

Claims

1. 1. An industrial robot maintenance system for performing maintenance on an industrial robot, the maintenance system returning the industrial robot after maintenance work to a pre-work posture that is a posture before the maintenance work was started, A worker terminal; An administrator terminal; Equipped with The worker terminal includes: Acquire the posture of the industrial robot before the work, and send a notification of the posture acquisition to the manager terminal; and transmitting an approval request to the manager terminal when it is confirmed that the posture of the robot has returned to the posture before the maintenance work after the maintenance work. Maintenance system for industrial robots.

2. The administrator terminal transmits a confirmation notification indicating that the notification of the posture acquisition has been received from the worker terminal.

2. The maintenance system for an industrial robot according to claim 1.

3. The administrator terminal transmits an approval notification indicating that the notification of the approval request has been received from the worker terminal.

3. A maintenance system for an industrial robot according to claim 1 or 2.

4. 1. An industrial robot maintenance system for performing maintenance on an industrial robot, the maintenance system returning the industrial robot after maintenance work to a pre-work posture that is a posture before the maintenance work was started, A worker terminal; A management device; Equipped with The worker terminal includes: Acquire the posture of the industrial robot before the work and send a notification of the posture acquisition to the management device; and transmitting an approval request to the management device when it is confirmed that the posture of the robot has returned to the posture before the maintenance work after the maintenance work. Maintenance system for industrial robots.

Images