Collaborative robot system

Abstract

This invention provides a collaborative robot system capable of detecting defects in the visual inspection section. [Solution] A collaborative robot system is used to work alongside a user. This collaborative robot system comprises a work robot that performs tasks involving gripping a workpiece, an inspection unit that performs visual inspection of the workpiece, a diagnostic unit that diagnoses abnormalities in the inspection unit, and a control unit that controls the operation of the work robot and stops the work robot's operation when the diagnostic unit diagnoses an abnormality in the inspection unit.

Description

Technical Field

[0001] This specification discloses a technology related to a collaborative robot system.

Background Art

[0002] Patent Document 1 discloses a technology for inspecting the appearance of a press-formed product, outputting an abnormal signal when surface defects of the product occur continuously a predetermined number of times, and detecting that there is a problem in the press device that is the source of the surface defects. Also, in Patent Document 1, the occurrence rate of surface defects of the product is calculated to recognize the tendency of problems in the press device, and it is used for the maintenance management of the press device.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The technology of Patent Document 1 mainly focuses on detecting surface defects of a product and preventing surface defects from occurring in the product. However, when there is a problem in the appearance inspection device, even if there are no surface defects in the product, it may be detected that there are surface defects in the product. If a product is judged to be a defective product although it is a non-defective product, it is necessary to discard the non-defective product or re-inspect the product judged to be a defective product. Therefore, it is also necessary to detect whether there is a problem in the appearance inspection device. This specification aims to provide a collaborative robot system that can detect the presence or absence of problems in the appearance inspection unit in a collaborative robot system for working with a user.

Means for Solving the Problems

[0005] The first technology disclosed herein is a collaborative robot system for working with a user, which may include a work robot that performs tasks involving gripping a workpiece, an appearance inspection unit that performs an appearance inspection of the workpiece, a diagnostic unit that diagnoses abnormalities in the appearance inspection unit, and a control unit that controls the operation of the work robot and stops the work of the work robot when the diagnostic unit diagnoses that an abnormality has occurred in the appearance inspection unit.

[0006] The second technology disclosed herein is a collaborative robot system of the first technology, wherein the diagnostic unit may diagnose that an abnormality has occurred in the visual inspection unit when the visual inspection unit detects an abnormality in the workpiece a predetermined number of consecutive times.

[0007] A third technology disclosed herein is a collaborative robot system of the first technology, wherein the control unit may resume the work of the work robot after the diagnostic unit has diagnosed that an abnormality has occurred in the visual inspection unit and it has been confirmed that no abnormality has occurred in the visual inspection unit.

[0008] A fourth technology disclosed herein is a collaborative robot system of any of the first to third technologies described above, further comprising a solar cell, the solar cell may supply power to the control unit. [Effects of the Invention]

[0009] According to the first technology, it is possible to determine whether or not there is an abnormality in the visual inspection unit. As a result, it is possible to prevent workpieces (products) from being judged as defective even though they are good products. This avoids discarding good workpieces and improves manufacturing yield. Alternatively, it prevents the re-inspection of workpieces that have been judged as defective. The determination of whether or not there is an abnormality in the visual inspection unit is made by inspecting whether or not the imaging device (camera) equipped in the visual inspection unit is dirty. This inspection can be done by providing the imaging device with a dirt-checking imaging mode, or by using the imaging device equipped in the work robot to image the imaging device of the visual inspection unit. According to the first technology, the collaborative robot system can self-diagnose whether or not there is an abnormality in the visual inspection unit without the user having to perform an inspection.

[0010] According to the second technology, abnormalities in the visual inspection section can be detected early. As a result, the occurrence of defects where good workpieces are mistakenly identified as defective can be reduced.

[0011] According to the third technology, if no abnormality occurs in the visual inspection unit, the robot can resume the visual inspection work without any user intervention.

[0012] According to the fourth technology, the amount of commercial electricity used can be reduced. [Brief explanation of the drawing]

[0013] [Figure 1] A perspective view of the collaborative robot system is shown. [Figure 2] This outlines the collaborative robot system. [Figure 3] This shows the abnormality detection flow for the visual inspection department. [Modes for carrying out the invention]

[0014] Referring to Figure 1, the collaborative robot system 90 will be described. The collaborative robot system 90 is used in factories and other facilities to work together with the user on the manufacturing floor. Specifically, the collaborative robot system 90 can be used with the work robot 10 to move products (workpieces) or to inspect products.

[0015] The collaborative robot system 90 comprises a mobile platform 30, a work robot 10 mounted on the mobile platform 30, and a light-shielding box 50 mounted on the mobile platform 30 at a different position from the work robot 10. The mobile platform 30 comprises a main body 32 and a plurality of wheels 34 attached to the main body 32. The mobile platform 30 is configured to move in multiple directions by having a plurality of wheels 34. The plurality of wheels 34 are attached to the lower part of the main body 32. The mobile platform 30 can move in multiple directions, for example, on a floor. The mobile platform 30 can be moved manually or automatically.

[0016] The main body 32 of the mobile platform 30 is configured, for example, in the shape of a box. The main body 32 has an upper surface 36 on which the work robot 10 and the box 50 are mounted. The main body 32 supports the work robot 10 and the box 50. The main body 32 is made of, for example, an aluminum alloy.

[0017] The work robot 10 is fixed to the upper surface 36 of the mobile platform 30. The work robot 10 is an articulated robot equipped with multiple arms. The work robot 10 can grasp a workpiece W and move the workpiece W. For example, the work robot 10 can move the workpiece W from outside to inside the box 50, or from inside to outside the box 50. The work robot 10 comprises a base end 12, an arm 18, a first imaging device 80, and a control unit 100. The base end 12 is fixed to the upper surface 36 of the mobile platform 30. The arm 18 comprises a first part 13, a second part 14, a tip 15, and a hand part 16.

[0018] The first part 13 is rotatably connected to the base end portion 12. The first part 13 can rotate about one or more axes. The second part 14 is rotatably connected to the first part 13. The second part 14 can also rotate about one or more axes. The tip end portion 15 is rotatably connected to the second part 14. The tip end portion 15 can also rotate about one or more axes. The hand portion 16 is connected to the tip end portion 15. The hand portion 16 includes, for example, a plurality of claw members, and can grip the workpiece W by the approach or separation of the plurality of claw members. The hand portion 16 is sometimes called a chuck.

[0019] The first imaging device 80 is attached to the tip end portion 15. The first imaging device 80 can image the workpiece W. The first imaging device 80 acquires an image of the workpiece W by imaging the workpiece W. The first imaging device 80 can acquire a still image and / or a moving image of the workpiece W. The first imaging device 80 is used when the hand portion 16 grips the workpiece W on a support base (not shown) or when the workpiece W is placed on the support base. Note that the first imaging device 80 may include an illumination device that illuminates the imaging object. Also, although details will be described later, the first imaging device 80 may image the second imaging device 70 provided in the box body 50.

[0020] Inside the main body 32 of the moving base 30, a control unit 100 that controls the work robot 10 is arranged. The control unit 100 includes, for example, a CPU, a ROM, a RAM, etc., and executes various controls and processes related to the work robot 10 based on a predetermined program. The control unit 100 can recognize the form (for example, shape, posture, position, angle) of the workpiece W based on the image captured by the first imaging device 80.

[0021] The box body 50 is fixed to the upper surface portion 36 of the moving base 30 at a position different from the working robot 10. The working robot 10 and the box body 50 are arranged side by side on the upper surface portion 36 of the moving base 30. The working robot 10 and the box body 50 are arranged facing each other. The box body 50 blocks the light outside the box body 50. That is, the box body 50 suppresses the light outside the box body 50 from entering the inside of the box body 50. A space capable of accommodating the workpiece W is formed inside the box body 50.

[0022] The box body 50 includes an upper member 51, a lower member 52, a left member 53, a right member 54, and a rear member 55. The upper member 51, the left member 53, the right member 54, and the rear member 55 block the light outside the box body 50 (suppress the light outside the box body 50 from entering the inside of the box body 50). For example, the upper member 51, the lower member 52, the left member 53, the right member 54, and the rear member 55 are formed of black plate-shaped members. A solar cell 62 is arranged on the upper part of the box body 50 (the upper part of the upper member 51). Further, an opening 60 is provided in the box body 50. The opening 60 is provided on the front side of the box body 50 (the side of the working robot 10). The opening 60 faces the working robot 10. In the collaborative robot system 90, the workpiece W is taken in and out of the box body 50 through the opening 60. Inside the box body 50, an appearance inspection of the workpiece W is performed.

[0023] A second imaging device 70 is attached to the left member 53 of the box body 50. The second imaging device 70 can image the inside of the box body 50. When the workpiece W exists inside the box body 50, the second imaging device 70 can image the workpiece W inside the box body 50. The second imaging device 70 acquires an image of the workpiece W by imaging the workpiece W. Thereby, an appearance inspection such as the shape of the workpiece W and the presence or absence of scratches can be performed. The second imaging device 70 is an example of an appearance inspection unit. The second imaging device 70 inspects whether the shape of the workpiece W conforms to the standard, that is, whether the workpiece W is a good product or a defective product. Note that the second imaging device 70 may include a lighting device that illuminates the imaging target.

[0024] A diagnostic unit 102 for determining abnormalities in the second imaging device 70 is located inside the main body 32 of the mobile platform 30. The diagnostic unit 102 is equipped with, for example, a CPU, ROM, and RAM, and diagnoses that there is an abnormality in the second imaging device 70 when the second imaging device 70 detects an abnormality in the workpiece W for a predetermined number of consecutive times (for example, 5 times) (when it detects a shape defect in the workpiece W). When the diagnostic unit 102 determines that there is an abnormality in the second imaging device 70, it transmits the result to the control unit 100.

[0025] When the control unit 100 receives a result from the diagnostic unit 102 indicating that an abnormality has occurred in the second imaging device 70, it stops the work of the work robot 10 (movement of the workpiece W). After stopping the work of the work robot 10, the control unit 100 uses the first imaging device 80 to capture still images and / or video of the second imaging device 70. Specifically, the control unit 100 uses the first imaging device 80 to image the lens of the camera provided in the second imaging device 70 and check for any dirt on the lens or other defects.

[0026] When the control unit 100 confirms that an abnormality (such as lens contamination) has occurred in the second imaging device 70, it notifies the control unit 100 of the abnormality in the second imaging device 70 using a notification device or other means (not shown). Furthermore, if the control unit 100 confirms that there is no abnormality in the second imaging device 70, that is, if a predetermined number of defective workpieces W have actually been handled consecutively, it restarts the operation of the work robot 10 (movement of workpieces W).

[0027] As described above, a solar cell 62 is provided on the top of the box 50. The power generated by the solar cell 62 is supplied to the control unit 100. Alternatively, the power generated by the solar cell 62 may be supplied directly to the control unit 100. Or, a battery (not shown) may be provided inside the main body 32 of the mobile stand 30, the power generated by the solar cell 62 may be supplied to the battery, and the power may be supplied from the battery to the control unit 100.

[0028] Referring to Figure 2, the features of the collaborative robot system 90 are summarized. In the collaborative robot system 90, the work robot 10 is used to move the workpiece W, and the second imaging device 70 is used to perform a visual inspection of the workpiece W. When the diagnostic unit 102 detects a shape defect in the workpiece W a predetermined number of times in a row, it transmits the result to the control unit 100. The control unit 100 then stops the work of the work robot 10. This prevents the collaborative robot system 90 from repeatedly misidentifying a normal workpiece W as a defective product.

[0029] In the collaborative robot system 90, after stopping the work of the work robot 10, the control unit 100 drives the work robot 10 and uses the first imaging device 80 to image the second imaging device 70. This allows the collaborative robot system 90 to self-diagnose whether or not there is any dirt (abnormality) on the camera lens etc. of the second imaging device 70. Furthermore, if there is no abnormality in the second imaging device 70, the control unit 100 can restart the work of the work robot 10 and continue the visual inspection of the workpiece W. In addition, since the collaborative robot system 90 is equipped with a solar cell 62, it can also reduce the amount of commercial electricity used.

[0030] Referring to Figure 3, the abnormality detection process of the second imaging device 70 will be explained. First, the work robot 10 moves the workpiece W into the box 50, and the second imaging device 70 takes an image of the workpiece W's appearance (step S2). Next, the second imaging device 70 detects whether or not there is an abnormality in the workpiece W based on the image of the workpiece W taken (step S4). If it is determined that there is no abnormality in the workpiece W (step S4: NO), the process returns to step S2 and the visual inspection of the workpiece W continues.

[0031] If it is determined that there is an abnormality in the appearance of the workpiece W (Step S4: YES), it is determined whether the abnormality in the appearance of the workpiece W has been detected five times in a row (Step S6). If the abnormality in the appearance of the workpiece W has been detected for the first time, or for two to four consecutive times, the process returns to Step S2 and the visual inspection of the workpiece W continues. On the other hand, if the abnormality in the appearance of the workpiece W has been detected five times in a row (Step S6: YES), the operation of the work robot 10 is stopped and the visual inspection of the workpiece W is discontinued (Step S6). Then, the second imaging device 70 is imaged using the first imaging device 80 and it is diagnosed whether there is an abnormality such as lens contamination in the second imaging device 70 (Step S12).

[0032] If the diagnosis of whether or not there is an abnormality in the second imaging device 70 reveals that there is no malfunction (abnormality) in the second imaging device 70 (step S12: NO), the process returns to step S2 and the visual inspection of the workpiece W continues. On the other hand, if there is a malfunction (abnormality) in the second imaging device 70 (step S12: YES), the process proceeds to step S14 and the system is notified that there is an abnormality in the second imaging device 70.

[0033] (Other embodiments) In the above embodiment, an example was described in which, if it is determined that an abnormality has occurred in the second imaging device 70, the first imaging device 80 is used to diagnose whether or not there is an abnormality in the second imaging device 70. However, the second imaging device 70 may be provided with a dirt detection mode, and the presence or absence of an abnormality in the second imaging device 70 may be diagnosed without using the first imaging device 80.

[0034] In the above embodiment, an example was described in which the solar cell 62 supplies power to the control unit 100. However, the solar cell 62 may also supply power to the diagnostic unit 102, the first imaging device 80, the second imaging device 70, etc. In the technology disclosed herein, the solar cell 62 is not an essential component and may be omitted.

[0035] In the above embodiment, an example was described in which, after the diagnostic unit 102 diagnoses that there is an abnormality in the second imaging device 70 and stops the work of the work robot 10, the control unit 100 resumes the work of the work robot 10 if it is confirmed that there is no abnormality in the second imaging device 70. However, the control unit 100 may maintain the suspension of the work of the work robot 10 even if it is confirmed that there is no abnormality in the second imaging device 70. In this case, the user can check the status of the work robot 10, the second imaging device 70, and the workpiece W, and check the environment around the collaborative robot system 90 before the work robot 10 resumes its work (visual inspection).

[0036] In the above embodiment, the diagnostic unit 102 was described in an example in which it diagnoses that there is a problem with the second imaging device 70 when the second imaging device 70 detects an abnormality in the workpiece W five times in a row. However, the number of consecutive abnormalities in the workpiece W that lead to a diagnosis of a problem with the second imaging device 70 may be four or fewer, or six or more.

[0037] Although embodiments of the present invention have been described in detail above, these are merely illustrative and do not limit the scope of the claims. The technologies described in the claims include various modifications and changes to the specific examples illustrated above. Furthermore, the technical elements described in this specification or drawings exhibit technical usefulness individually or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technologies illustrated in this specification or drawings achieve multiple objectives simultaneously, and achieving even one of these objectives constitutes technical usefulness in itself. [Explanation of symbols]

[0038] 10: Work robots 70: Second imaging device (visual inspection section) 100: Control Unit 102: Diagnostic Department W: Work

Claims

1. A collaborative robot system for working together with the user, A robot that performs tasks involving gripping a workpiece, An appearance inspection unit that performs an appearance inspection of the aforementioned workpiece, A diagnostic unit for diagnosing abnormalities in the aforementioned visual inspection unit, A control unit that controls the operation of the work robot and stops the work of the work robot when the diagnostic unit diagnoses that an abnormality has occurred in the visual inspection unit, A collaborative robot system equipped with [a specific feature / ability].

2. A collaborative robot system according to claim 1, The diagnostic unit is a collaborative robot system that diagnoses that an abnormality has occurred in the visual inspection unit when the visual inspection unit detects an abnormality in the workpiece a predetermined number of times consecutively.

3. A collaborative robot system according to claim 1, The control unit, after the diagnostic unit has diagnosed that an abnormality has occurred in the visual inspection unit, and after it has been confirmed that no abnormality has occurred in the visual inspection unit, restarts the work of the work robot in this collaborative robot system.

4. A collaborative robot system according to any one of claims 1 to 3, Furthermore, it is equipped with solar panels. The aforementioned solar cell supplies power to the control unit in a collaborative robot system.

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