Binding device and binding program

Abstract

This provides a simple way to determine whether or not intersections can be joined. [Solution] The binding system 1 includes a binding machine 61 capable of binding a three-dimensional workpiece B including an intersection point P, a robot arm 4 capable of moving the binding machine 61 and the workpiece B relative to each other, a first camera 31 for observing the workpiece B in two dimensions, and a control device 7. The control device 7 determines whether the intersection point P and the binding machine 61 can approach each other based on the information of the workpiece B observed by the first camera 31.

Description

Technical Field

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

Background Art

[0002] Conventionally, there has been known a bundling system that automatically and sequentially bundles the intersections of intersecting reinforcing bars with a wire for a workpiece in which a plurality of reinforcing bars are combined. In this type of bundling system, information on the bundling points, which are the intersections of the reinforcing bars, may be acquired by sensors or cameras. For example, in the technique described in Patent Document 1, the planar shape of the frontmost surface of the workpiece including the intersections is detected by a three-dimensional camera. Also, in the technique described in Patent Document 2, the coordinates of the intersections are specified from an image of the workpiece photographed by a camera.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in the bundling of a three-dimensional object to be bundled, there may be a case where an object to be bundled or the like is disposed between the intersection and the bundling machine, interfering with the bundling operation of the bundling machine. Therefore, it is useful for the smooth progress of the bundling work if it is possible to simply determine whether or not bundling at the intersection is possible before bundling.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to simply determine whether or not bundling at an intersection is possible.

Means for Solving the Problems

[0006] To solve the above-mentioned problems, the present invention provides a binding device, A binding section capable of binding three-dimensional objects including intersections, A movable part that allows the binding part and the object to be bound to move relative to each other, An observation unit for observing the bundled object in two dimensions, A determination unit determines whether the intersection and the binding portion can approach each other based on the information of the bound object observed by the observation unit, It is equipped with. [Effects of the Invention]

[0007] According to the present invention, based on the information of the object to be bound observed by the observation unit, it is determined whether or not the intersection point in the object to be bound and the binding part can approach each other. Based on the determination result of whether or not the intersection point can be bound, it is possible to determine whether or not the intersection point can be bound. Therefore, it is possible to easily determine whether or not the intersection point can be bound. [Brief explanation of the drawing]

[0008] [Figure 1] This is a perspective view of the main body of the bundling system according to the embodiment. [Figure 2] This is a block diagram showing a schematic control configuration of the bundling system according to the embodiment. [Figure 3] This is a side view of a bundling device according to an embodiment. [Figure 4] This is a perspective view showing an example of a workpiece according to the embodiment. [Figure 5] This figure shows the reinforcement bar arrangement model for the workpiece shown in Figure 4. [Figure 6] This is a flowchart showing the procedure for the bundling process according to the embodiment. [Figure 7] This is a flowchart showing the procedure for the bundling process according to the embodiment. [Figure 8] This figure shows an example of a workpiece with truss reinforcement placed on a panel. [Figure 9] This figure shows an example of an image taken of the workpiece shown in Figure 8. [Modes for carrying out the invention]

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

[0010] [Configuration of the tying system] FIG. 1 is a perspective view of the apparatus main body 10 included in the tying system 1 according to the present embodiment, and FIG. 2 is a block diagram showing a schematic control configuration of the tying system 1. As shown in these figures, the tying system 1 ties a workpiece B (object to be tied) in which a plurality of reinforcing bars S are arranged in a three-dimensional lattice shape at intersections where the plurality of reinforcing bars S intersect. The tying system 1 corresponds to an example of the tying device according to the present invention. Specifically, the tying system 1 includes an apparatus main body 10 and a control device 7.

[0011] The apparatus main body 10 includes a workpiece holding unit 2, an overall imaging unit 3, a robot arm 4, an individual imaging unit 5, and a tying device 6. Among these, the workpiece holding unit 2 is disposed inside the pedestal 11 of the apparatus main body 10, and the overall imaging unit 3, the robot arm 4, the individual imaging unit 5, and the tying device 6 are mounted on the pedestal 11. In the following description, each direction of XYZ refers to the direction shown in FIG. 1. Each direction of XYZ is orthogonal to each other, the XY plane is a substantially horizontal plane, and the Z direction is a direction substantially along the vertical direction.

[0012] The pedestal 11 is formed in a rectangular parallelepiped shape that is long in the X direction, and includes four columns 12 erected at the four corners in the X direction and the Y direction, and four beams 13 spanned in the X direction and the Y direction at the upper ends of the columns 12. Among the regions inside the pedestal 11, a substantially half portion on one side in the X direction (the right side in FIG. 1) is an imaging area E1 where imaging by the overall imaging unit 3 is performed, and the other half portion (the left side in FIG. 1) is a tying area E2 where tying work by the robot arm 4 and the tying device 6 is performed.

[0013] [Workpiece holding unit] The workpiece holding unit 2 holds the workpiece B and moves the held workpiece B between the imaging area E1 and the tying area E2. The workpiece B of this embodiment is a reinforcing bar structure in which a plurality of main reinforcing bars S1 and a plurality of stirrups S2 are three-dimensionally combined. Each of the main reinforcing bars S1 extends along the X direction, and a plurality of them are arranged in parallel in the Y direction and the Z direction (in the example of FIG. 1, three are arranged in parallel in the Y direction and two are arranged in parallel in the Z direction). Each of the stirrups S2 is arranged in a strip shape so as to go around the outside of the plurality of main reinforcing bars S1 along the YZ plane, and a plurality of them are arranged in parallel along the X direction. Before the plurality of reinforcing bars S (main reinforcing bars S1 and stirrups S2) are bundled, each reinforcing bar S is held by a jig (not shown) in the workpiece B.

[0014] The workpiece holding part 2 includes a holding table 21 for holding the workpiece B, a rail 22 for movably supporting the holding table 21, and a drive motor 23 for driving the rail 22. The holding table 21 is formed in a rectangular plate shape with four sides along the X direction and the Y direction. The rail 22 is laid along the X direction and guides the holding table 21 in the X direction. The rail 22 of this embodiment is laid so that the holding table 21 (workpiece B) can move at least between the imaging area E1 and the bundling area E2. However, the rail 22 may be extended to the outside of the gantry 11 so that the workpiece B can be moved to the work processes before and after bundling. The drive motor 23 is a drive source for moving the holding table 21. The drive motor 23 moves the holding table 21 to the imaging area E1 and the bundling area E2 based on a drive command from the control device 7. Note that the workpiece holding part 2 only needs to be able to move the holding table 21 (workpiece B) from the imaging area E1 to the bundling area E2 at least.

[0015] <Overall imaging part> The overall imaging part 3 images the entire workpiece B in the imaging area E1. Specifically, the overall imaging part 3 includes a first camera 31 arranged above the imaging area E1 and a moving mechanism 32 for movably supporting the first camera 31. The first camera 31 is positioned facing downwards and photographs the workpiece B held by the workpiece holding unit 2 from above in the shooting area E1. The first camera 31 in this embodiment is a compound-lens (e.g., 4-lens) stereo camera that acquires distance information in the depth direction (vertical direction) along with image information (monochrome image) in the XY plane and outputs it to the control device 7. The first camera 31 corresponds to an example of the observation unit according to the present invention.

[0016] The moving mechanism 32 includes a Y-direction slider 33 that extends along the Y-direction. The Y-direction slider 33 is spanned on a beam 13 along the X-direction and is supported on the beam 13 so as to be movable in the X-direction. The first camera 31 is suspended from the Y-direction slider 33 so as to be movable in the Y-direction. Based on control commands from the control device 7, the moving mechanism 32 drives a drive source (not shown) to move the first camera 31 to a predetermined position (XY coordinates). Furthermore, as will be described later, the moving mechanism 32 is for capturing images of the entire workpiece B in multiple stages 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 be used to move the first camera 31 in only one direction, either X or Y, or it may not be provided at all.

[0017] <Robot Arm> The robot arm 4 is equipped with an individual imaging unit 5 and a binding device 6, and moves the individual imaging unit 5 and the binding device 6 to a desired position in the binding area E2. The robot arm 4 is an example of a moving unit according to the present invention, and is capable of moving the binding device 6 and the workpiece B relative to each other. The robot arm 4 of this embodiment comprises a moving mechanism 46, a robot arm body 40, and a controller 49.

[0018] The moving mechanism 46 moves the robot arm body 40. In this embodiment, the moving mechanism 46 includes a Y-direction slider 461 that spans the beam 13 of the frame 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. Also, 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.

[0019] The robot arm body 40 is a ceiling-mounted vertical articulated robot, and is installed facing downwards on a Y-direction slider 461 that spans the beam 13 in the binding area E2. Specifically, the robot arm body 40 comprises a base section 41, multiple arms 42, an end effector 43, and multiple joint sections 44. Furthermore, the robot arm body 40 is not limited to a vertical articulated robot, as long as it is capable of moving the mounted individual imaging units 5 and binding device 6.

[0020] Multiple arms 42 are connected in series to each other, with the base portion 41 as the base end. The base portion 41 is mounted on the Y-direction slider 461 of the moving mechanism 46 and is supported so as to be movable in the Y direction. Multiple joints 44 rotatably connect the base 41, multiple arms 42, and end effectors 43. Each joint 44 is provided with a motor 441 that drives the arm 42 (or end effector 43) connected to the tip of the joint 44, and an encoder 442 that detects the position (speed) of the motor 441 and outputs it to the controller 49. The end effector 43 is connected to the tips of multiple arms 42. The end effector 43 is equipped with an individual imaging unit 5 and a binding device 6. The specific configuration of the tip of the robot arm body 40 is not particularly limited, as long as it is equipped with an individual imaging unit 5 and a binding device 6. For example, the individual imaging unit 5 may be fixed to the furthest joint 44, and the binding device 6 may be connected as an end effector via a tool changer.

[0021] The controller 49 controls the movement of each part of the robot arm 4 based on control commands from the control device 7. Specifically, the controller 49 operates each motor 441 and the movement mechanism 46, and outputs information acquired by each encoder 442 to the control device 7. The controller 49 may also locally control the operation of the mounted individual imaging units 5 and the bundling device 6 based on control commands from the control device 7.

[0022] <Individual Photography Section> The individual imaging unit 5 is mounted at the tip of the robot arm body 40 and individually photographs the intersection points P (see Figure 4) of the reinforcing bars S to be tied in the tying area E2 with a higher resolution than the overall imaging unit 3. Specifically, the individual imaging unit 5 comprises a second camera 51, a lifting motor 52, and a lighting unit 53. The second camera 51 is mounted on the end effector 43 of the robot arm 4, facing downwards, and photographs the intersection P of the reinforcing bars S to be tied from above. The second camera 51 is provided so as to be movable in the direction of the end effector 43 (up and down). In this embodiment, the second camera 51 is, for example, an RGB camera, and acquires image information (color image) of the intersection P to be tied and outputs it to the control device 7. The lifting motor 52 is a drive source that moves (lifts and lowers) the second camera 51 toward the tip (up and down) relative to the end effector 43. The lighting unit 53 is positioned slightly in front of the second camera 51 and around the shooting range, illuminating the object being photographed by the second camera 51. The lighting unit 53 in this embodiment has multiple light sources (floodlights; not shown) that can illuminate the object being photographed by the second camera 51 from different angles.

[0023] <Binding device> Figure 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 body 40. The binding device 6 comprises a rebar binding machine (hereinafter simply referred to as "binding machine") 61 that binds the intersections P of the reinforcing bars S that make up the workpiece B with wire W, a slack-forming unit 62 that pulls out the wire W from the reel 63 and forms slack in the wire W between the binding machine 61 and the reel 63, and a control unit 64 (see Figure 2) that executes the binding operation of the binding machine 61 and the slack-forming operation of the wire W of the slack-forming unit 62 according to operation commands from the control device 7.

[0024] The binding machine 61 has an inlet 611 into which two wires W are fed from outside the housing along the feeding direction F shown in the figure. The two wires W fed into the interior from the inlet 611 are wrapped around the reinforcing bar S, and the two wires W wrapped around the reinforcing bar S are fed in the reverse feeding direction R to wrap around the reinforcing bar S and cut, after which the wires W are twisted and the reinforcing bar S is bound together with the wires W.

[0025] Therefore, the binding machine 61 includes a wire feeding section for feeding the wire W, a wire guide 612 for guiding the wire W, a curl guide 613 and a guide 614 for winding the wire W around the reinforcing bar S, a cutting section for cutting the wire W wound around the reinforcing bar S, and a wire twisting section for twisting the wire W wound around the reinforcing bar S.

[0026] The wire guide 612 is provided in front of the entrance 611 and guides the two wires W to enter the entrance 611 along the feeding direction F.

[0027] The wire feeding section is located inside the entrance section 611 and feeds two wires W along the feeding direction F by gripping them with a pair of feed gears. The wire feeding section is equipped with a feed motor 615 (see Figure 2) which serves as the drive source. By driving the feed motor 615 in the forward direction, the two wires W are fed in the feeding direction F, allowing the wires W to be wound around the reinforcing bar S by the curl guide 613 and guide guide 614 located further along the path. The feed motor 615 can also drive the two wires W in the reverse direction R, allowing the reinforcing bar S to be tightened by the wires W.

[0028] The cutting section is located inside the entrance section 611 and further inside the wire feeding section. The cutting section has a movable blade and a fixed blade (not shown), and the drive source for the movable blade is shared with the wire twisting section. The movable blade can be moved toward the fixed blade by the twisting motor 616 (see Figure 2), which is the drive source for the wire twisting section, to cut two wires. The drive source for the cutting section may be provided separately and independently.

[0029] The binding device 6 in Figure 3 is supported by an end effector 43 at the tip of the robot arm 4, and performs the binding operation when the pivot axis Zr of the end effector 43 is parallel to the aforementioned Z direction (vertical up and down direction). Furthermore, 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 pivot axis Zr, and during binding, the robot arm 4 positions the binding device 6 so that the intersection point P of the reinforcing bar S is on the axis of the pivot axis Zr.

[0030] The curl guide 613 and the guide 614 are located at the tip of the strapping machine 61 (the lower end during strapping operation), and are positioned on either side of the aforementioned pivot axis Zr. The curl guide 613 is positioned with its base end located beyond the entrance portion 611 in the feeding direction F, and a guide path is formed on the inside of the curl guide 613 to curl the wire W as it moves from the base end to the tip end.

[0031] The guide 614 is positioned opposite the curl guide 613 and has a guide path formed on its inside that receives the wire W, which has been curled by the curl guide 613, from the tip and guides the wire W to the base end while maintaining the curled state. Through the cooperation of these curl guides 613 and guide 614, the wire W can be deformed into a loop and wrapped around the reinforcing bar S. Furthermore, the curl guide 613 and the guide 614 are straight arms with their inner surfaces parallel to the pivot axis Zr. In other words, as will be described later, the inner surfaces of the curl guide 613 and the guide 614 are parallel to the direction of approach between the intersection point P of the reinforcing bars S and the binding machine 61.

[0032] The wire twisting section has a locking member that captures the wire W while it is wound around the reinforcing bar S between the base end of the guide 614 and the base end of the curl guide 613. The locking member is supported inside the binding machine 61 so as to be rotatable around a rotation axis concentric with the aforementioned pivot axis Zr, and is provided with torque for rotational drive by the aforementioned twisting motor 616. After the wire W is cut by the cutting section, the locking member is rotated by the twisting motor 616, twisting both ends of the wire W to bind the reinforcing bar S.

[0033] On one side of the binding machine 61 in the direction along its pivot axis Zr (the upper side during binding), two reels 63 of wire W are rotatably supported side by side. The two reels 63 are each rotatable around an axis along the direction perpendicular to the plane of the paper in Figure 3, and are arranged side by side on that axis.

[0034] The slack-forming section 62 is positioned on one side of the binding machine 61 and the two reels 63 in an orthogonal direction Xw perpendicular to the pivot axis Zr. The slack-forming section 62 includes 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 the driving source for these passing movements.

[0035] The feed direction F of the wire W, as described above, is roughly parallel to a plane that is parallel to the pivot axis Zr and the orthogonal direction Xw. Furthermore, the feed direction F of the wire W is inclined somewhat upward in the plane of Figure 3 relative to the orthogonal direction Xw on the upstream side. The first slack-forming section 621 and the second slack-forming section 622 both hold rollers over which the two wires W are stretched.

[0036] The first slack-forming section 621 and the second slack-forming section 622 then move in a passing motion generally along the feeding direction F, thereby extending the path length of the wire W from the reel 63 to the entrance 611 of the binding machine 61 and pulling the wire W out from the reel 63. In addition, the first slack-forming section 621 and the second slack-forming section 622 then move back after the passing motion, thereby adding slack to the wire W by the amount it was pulled out from the reel 63. The slack-forming portion 62 does not necessarily need to be provided.

[0037] Incidentally, the two wires W are required to be fed into the entrance 611 of the binding machine 61 from a direction close to the feeding direction F (i.e., an incidence angle close to the feeding direction F). The feeding direction F is a suitable direction for deforming the wires W into an appropriate loop shape by the curl guide 613 and guide guide 614 located ahead of that direction of travel. In order to supply the wire W to the inlet 611 of the binding machine 61 along the feeding direction F, the slack-forming unit 62 is positioned such that the path from the downstream second slack-forming unit 622 to the inlet 611 of the binding machine 61 is along the feeding direction F. When passing another unit, the second slack-forming unit 622 moves away from the inlet 611 of the binding machine 61 along the feeding direction F.

[0038] Therefore, the binding device 6 is positioned such that the slack-forming portion 62 protrudes significantly from one side (the right side of the page in Figure 3) in the direction Xw perpendicular to the binding machine 61 (rotating axis Zr). In addition, the second camera 51 and lighting unit 53 of the individual imaging unit 5 are located on the left side of the paper in Figure 3 relative to the binding machine 61 of the binding device 6.

[0039] <Control device> As shown in Figure 2, the control device 7 is a computer that comprehensively controls the bundling system 1. Specifically, the control device 7 comprises an operation unit 72, a display unit 73, a storage unit 76, and a control unit 77. The operation unit 72 is an operating means that allows the user to perform various operations to operate the control device 7, and includes, for example, a pointing device such as a mouse or a keyboard. The display unit 73 is composed of, for example, a liquid crystal display, an organic EL display, or other display, and displays various information based on display signals from the control unit 77. The display unit 73 may also be a touch panel that serves as part of the operation unit 72, or it may provide audio output.

[0040] The memory unit 76 is composed of RAM (Random Access Memory), ROM (Read Only Memory), etc., and stores various programs and data, as well as functioning as a workspace for the control unit 77. The storage unit 76 of this embodiment pre-stores a binding program 761, a rebar arrangement model 764, and binding part shape information 765 for executing the binding process described later, as well as image data 762 acquired during the binding process.

[0041] Image data 762 is image information of workpiece B (reinforcement bar S) acquired by the first camera 31 and the second camera 51 during the execution of the binding process described later. The binding section shape information 765 is information about the size and shape of the binding machine 61, and in this embodiment, it includes information about the two-dimensional shape of the binding machine 61 as viewed from the direction of approach (movement direction) between the intersection P and the binding machine 61. Specifically, the information about the two-dimensional shape of the binding machine 61 is, for example, information about the two-dimensional shape of the curl guide 613 and the guide guide 614 as viewed from the tip side (lower side of Figure 3) along the pivot axis Zr. The rebar arrangement model 764 is arrangement information of multiple reinforcing bars S in workpiece B, and is a skeletal model that skeletonizes the reinforcing bars S (showing the virtual centerlines of the reinforcing bars S in three dimensions). An example of the rebar arrangement model 764 in the case of workpiece B shown in Figure 4 is shown in Figure 5. The rebar arrangement model 764 includes, for example, information on the number of reinforcing bars S arranged in each XYZ direction. In addition, it may also include information such as the spacing between reinforcing bars S in each XYZ direction, and information on the angle if the reinforcing bars S are inclined. The data format of the rebar arrangement model 764 is not particularly limited and may be image data or numerical coordinate data. Furthermore, the storage unit 76 may record various other data acquired during the binding process described later, as needed.

[0042] The control unit 77 is composed of, for example, a CPU (Central Processing Unit) and controls the operation of each part of the control device 7. Specifically, the control unit 77 operates each part of the control device 7 based on the operation content of the operation unit 72, and also loads programs pre-stored in the storage unit 76 and executes various processes in cooperation with the loaded programs.

[0043] [Operation of the bundling system] Next, we will explain the operation of the binding system 1 when performing the binding process to bind workpiece B. Figures 6 and 7 are flowcharts showing the procedure for the binding process, and Figures 8 and 9 are diagrams illustrating the binding process. Figure 8 shows an example of a workpiece B with truss reinforcement T placed on a panel N, and Figure 9 shows an example of an image taken of workpiece B from Figure 8.

[0044] In the tying process, multiple reinforcing bars S arranged in a three-dimensional shape are tied together at the intersection points P (see Figure 4) where the multiple reinforcing bars S intersect. This tying process is performed when the control unit 77 of the control device 7 reads the tying program 761 from the storage unit 76 and loads it. Here, we assume that workpiece B is already placed on the holding base 21 and positioned in the shooting area E1 (see Figure 1). In the following, it is assumed that the control device 7 (specifically its control unit 77) executes each process, but the control entity for the bundling process is not particularly limited. For example, each component (or its control unit) of the bundling system 1 may execute the process, or the control device 7 and each component may cooperate to execute it.

[0045] As shown in Figure 6, when the bundling process is performed, the control unit 77 of the control device 7 first photographs the workpiece B in the shooting area E1 using the first camera 31 of the overall shooting unit 3 (step S1). Here, the control unit 77 acquires image data (monochrome image) in the XY plane, including distance information, for the entire workpiece B using the first camera 31, which is a stereo camera, and stores it in the storage unit 76. More specifically, the control unit 77 controls the movement mechanism 32 to move the first camera 31 in the XY plane according to the size of the workpiece B and the field of view of the first camera 31, and takes pictures of the entire workpiece B by dividing it into multiple parts (for example, 2x2 divisions in each XY direction) while partially overlapping. Then, the control unit 77 combines the acquired multiple images to generate an image of the entire workpiece B and stores it in the storage unit 76.

[0046] Next, the control unit 77 calculates the positions of all intersection points 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 the XYZ coordinates, for each intersection point P. In this step, it is sufficient to calculate the positions of multiple intersection points P out of all the intersection points P that workpiece B has. Alternatively, when calculating the position of intersection point P, the rebar arrangement model 764 may be used. In this case, the position is easier to calculate because the intersection point P is considered to be the point where the shape matches the rebar arrangement model 764.

[0047] Next, the control unit 77 performs an accessibility determination (step S21) to determine whether each intersection P whose position was calculated in step S2 can approach the strapping machine 61. Here, it is determined whether the intersection P and the strapping machine 61 can approach each other based on the shape information of the strapping machine 61 which is stored in advance as strapping part shape information 765 and the information of the intersection P observed by the first camera 31. Specifically, in this approach feasibility determination, as shown in Figure 7, the control unit 77 first selects the intersection P to be determined (step S22).

[0048] Next, the control unit 77 sets a predetermined shape of determination area (observation range) G (see Figure 9) centered on the intersection point P to be determined in the image data acquired in step S1 (step S23). Here, the determination area G can be set on the two-dimensional image data. The size and shape of the determination area G are not particularly limited, but for example, they correspond to the two-dimensional shape of the binding machine 61. The control unit 77 reads the binding part shape information 765 from the storage unit 76 and sets the determination area G. In this embodiment, the determination area G corresponds to the two-dimensional shape of the curl guide 613 and the guide guide 614 as viewed from the tip side along the pivot axis Zr, and is a long trapezoid or ellipse along the curl guide 613 and the guide guide 614. The size and shape of the judgment area G may be predetermined or selected by the user.

[0049] Next, the control unit 77 determines whether the area ratio occupied by the intersection point P in the determination area G is less than a predetermined threshold (step S24). Here, "the area ratio occupied by intersection P" refers to the area ratio of the reinforcing bars S (which constitute intersection P). In other words, in this step, the area ratio of the reinforcing bars S that may act as an obstacle to the insertion of the binding machine 61 is determined. For example, consider a workpiece B in which truss reinforcement bars T are arranged on a planar panel N as shown in Figure 8, and an image as shown in Figure 9 is acquired by the first camera 31. In this case, at intersection P1, which coincides with the center of the truss reinforcement bars T (center left and right in Figure 9), the area ratio of the reinforcement bars S to the trapezoidal judgment area G is less than the threshold, and it can be determined that the binding machine 61 can be inserted (approached). On the other hand, at intersection P2, which coincides with the end of the truss reinforcement bars T (right side in Figure 9), the proportion of the truss reinforcement bars T is large, and the area ratio of the reinforcement bars S to the elliptical judgment area G is greater than or equal to the threshold. In this case, it is determined that the binding machine 61 cannot be inserted (approached) at intersection P2.

[0050] In step S24, it is preferable for the control unit 77 to determine whether the binding machine 61 can approach (insert) the intersection P in multiple insertion directions (insertion positions). In this case, for example, it is determined whether the curl guide 613 and the guide 614 can be inserted into the intersection P in positions along the 2 o'clock, 4 o'clock, 8 o'clock, and 10 o'clock directions. However, it is assumed that two reinforcing bars S are arranged along the 3 o'clock-9 o'clock direction and the 12 o'clock-6 o'clock direction at the intersection P. Furthermore, in step S24, instead of determining the area ratio of intersection P (reinforcement bar S), the determination may be made regarding the area ratio of the space. "Space" refers to a space in which no objects are detected and into which the binding machine 61 can be inserted. In other words, in step S24, it may be determined whether the area ratio of the space into which the binding machine 61 can be inserted in the determination area G is equal to or greater than a threshold.

[0051] In step S24, if it is determined that the area ratio occupied by the intersection P (reinforcement bar S) within the determination area G is not less than the threshold (step S24; No), the control unit 77 determines that the binding machine 61 cannot approach the intersection P to be determined (step S25). The control unit 77 then records the determination result in the storage unit 76 and proceeds to step S27, which will be described later. Furthermore, if it is determined that the area ratio of intersection P to the judgment area G is not less than a threshold, the first camera 31 may be moved and the intersection P may be photographed, and the judgment in step S24 may be performed again. In other words, in this case, the first camera 31 is moved by a predetermined amount in the XY plane, for example, to obtain an image of intersection P from a different observation position (shooting position), and the judgment in step S24 is performed again using this image. This process may be performed for each intersection P, or it may be performed for multiple intersection P at once. In addition, the number of times this process is performed (or the movement limit of the first camera 31) may be set, and if the number of times is exceeded, it may be determined that the binding machine 61 cannot approach the intersection P.

[0052] In step S24, if it is determined that the area ratio occupied by the intersection P within the determination area G is less than the threshold (step S24; Yes), the control unit 77 determines that the bundling machine 61 can approach the intersection P (step S26), and records the determination result in the storage unit 76.

[0053] Next, the control unit 77 determines whether or not it has determined whether or not it is possible to approach all the intersection points P whose positions were calculated in step S2 (step S27). If it is determined that the feasibility of approaching all intersections P has not been determined (step S27; No), the control unit 77 proceeds to step S22 described above and determines the feasibility of approaching the next intersection P. On the other hand, if the possibility of approaching all intersection points P is determined (step S27; Yes), the control unit 77 terminates the approachability determination.

[0054] Next, as shown in Figure 6, the control unit 77 drives the drive motor 23 of the workpiece holding unit 2 to operate the holding table 21 and move the workpiece B to the binding area E2 (step S3).

[0055] Next, the control unit 77 selects an intersection P from among the multiple intersections P included in the workpiece B to be used for binding (step S4). Here, the control unit 77 selects one of several intersections P to be used for binding next, based, for example, on a pre-set binding order. However, intersections P that have already been bound (or are recognized as such) and intersections P that were determined in step S25 to be inaccessible to the binding machine 61 are excluded from the selection. Hereafter, the intersection point P selected here to be the next point to be bound will be referred to as the "target intersection point Pa".

[0056] Next, the control unit 77 moves the second camera 51 of the individual imaging unit 5 mounted on the robot arm 4 closer to the target intersection Pa selected in step S4 in the binding area E2 (step S5). Here, the control unit 77 controls the movement of the robot arm 4 based on the position information of the target intersection Pa calculated in step S2 and the amount of movement of the workpiece B in the X direction moved in step S3, moving the second camera 51 to directly above the target intersection Pa. Then, the control unit 77 controls the movement of the lifting motor 52 to lower the second camera 51 and bring it closer to the target intersection Pa by a predetermined distance. As a result, the target intersection Pa is positioned directly in front of the downward-facing second camera 51, and for example, only the target intersection Pa is within the field of view of the second camera 51 (the other intersections P are outside the field of view).

[0057] Next, the control unit 77 uses the second camera 51, which was brought closer in step S5, to photograph the target intersection Pa and acquire the image data (step S6). Here, the control unit 77 acquires image data (color image) of the target intersection Pa using the second camera 51 and stores it in the storage unit 76. This results in image data 762 of the target intersection Pa with higher resolution than the image data acquired by the first camera 31 in step S1. In this step, the control unit 77 may control the lighting unit 53 to photograph the target intersection Pa with multiple different lighting patterns. This allows for the generation of a three-dimensional image based on changes in the patterns of projected and reflected light, and the acquisition of distance information.

[0058] Next, the control unit 77 calculates the position of the target intersection point Pa based on the image data acquired in step S6 (step S7).

[0059] In calculating the target intersection point Pa, the control unit 77 first detects the edges of the reinforcing bar S, which are the contours of the reinforcing bar S in the image, based on the contrast information contained in the image data of the reinforcing bar S. Here, the contour (edge) refers to the boundary portion between the target reinforcing bar S and the rest of the image. Next, the control unit 77 calculates the rebar diameter (diameter of the rebar S) and the rebar center (central axis along the longitudinal direction of the rebar S) based on the edge position information. Next, the control unit 77 calculates the position of the target intersection point Pa. Here, the control unit 77 determines the position (coordinates) of the target intersection point Pa as, for example, the intersection of the centers of two reinforcing bars. In addition, the dimensions of the target intersection point Pa can also be obtained from the dimensions of the reinforcing bars S in each X and Y direction. 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 can be obtained.

[0060] The control unit 77 may also determine here whether or not the target intersection Pa can be tied. In this case, the control unit 77 determines, for example, whether or not the main part of the tying device 6 (such as the curl guide 613) can be inserted from above between the two reinforcing bars S, based on the intersection angle of the two reinforcing bars S, and determines that tying is possible if it determines that insertion is possible. If it is determined that tying is not possible, the control unit 77 moves on to other processes, including, for example, interrupting the work or outputting a warning. Furthermore, the control unit 77 may determine the binding direction based on the position and orientation of the binding device 6, which can be inserted between the two reinforcing bars S. In addition, the control unit 77 may calculate the wire length (including the pull-back length) required for binding the target intersection Pa based on the diameters and intersection angles of the two reinforcing bars S that constitute the target intersection Pa.

[0061] Next, 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 (step S8). Here, the control unit 77 controls the movement of the robot arm 4 and moves the binding device 6 mounted on the end effector 43 closer to the target intersection Pa, replacing the second camera 51. Here, based on the more accurate positional information of the target intersection Pa obtained in step S7, the control unit 77 can position the corresponding part of the binding device 6 facing the target intersection Pa with high positional accuracy.

[0062] In this case, the control unit 77 may move the strapping machine 61 along a straight line connecting a predetermined position (point) on the strapping machine 61 and the center of the target intersection Pa. The predetermined position on the strapping machine 61 is, for example, the center position on the pivot axis Zr between the curl guide 613 and the guide guide 614. This allows the strapping machine 61 to be moved to the target intersection Pa in the shortest distance. Furthermore, at this time, the control unit 77 may bring the target intersection Pa and the binding machine 61 closer together while aligning the pivot axis Zr (torsion axis) parallel to the line connecting a predetermined position (point) on the binding machine 61 and the center of the target intersection Pa. This allows the binding machine 61 to be inserted with the pivot axis Zr perfectly perpendicular to the target intersection Pa, enabling strong binding. Furthermore, at this time, the control unit 77 may move the target intersection Pa and the binding machine 61 closer together by having a predetermined movable range (allowable range) in a direction perpendicular to the direction connecting the target intersection Pa and the binding machine 61. In other words, the position of the binding machine 61 approaching the target intersection Pa may be shifted within the allowable range.

[0063] 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 positioned opposite the target intersection Pa with sufficiently high positional accuracy, so that the target intersection Pa can be bound effectively. At this time, the amount of wire W used to tie the target intersection Pa may also be calculated and stored in the memory unit 76. The amount of wire W used can be estimated from the actual wire feed amount (excluding the pull-back amount) in the wire feed unit. Also, if the wire length required for tying is estimated in step S7 described above, this may be used as the amount of wire W used.

[0064] Next, the control unit 77 determines whether or not to terminate the bundling process (step S10). If it determines not to terminate the process (step S10; No), it proceeds to step S4 described above. As a result, steps S4 to S10 are repeated until, for example, all necessary intersections P are bound together. In other words, the selection of the next intersection P to be bound (change of the target intersection Pa), the photography of that target intersection Pa, and the binding are performed sequentially. Then, in step S10, if it is determined that the binding process should be terminated, for example, by completing the binding of all necessary intersections P (step S10; Yes), the control unit 77 terminates the binding process.

[0065] [Technical effects of this embodiment] As described above, according to this embodiment, based on the information of the workpiece B observed two-dimensionally by the first camera 31 (observation unit), it is determined whether or not the intersection P and the binding machine 61 can approach each other. This allows us to determine whether the intersection points P can be joined based on the determination of whether they can approach each other. Therefore, we can easily determine whether the intersection points can be joined without requiring complex calculations such as processing three-dimensional images.

[0066] Furthermore, according to this embodiment, it is determined whether the binding machine 61 can approach the intersection P based on the binding shape information 765 stored in the memory unit 76 and the information of the intersection P observed by the first camera 31. Therefore, by comparing the information of intersection P with the shape of the binding machine 61, it is possible to determine with high accuracy whether or not the binding machine 61 can be inserted into intersection P, i.e., whether or not binding is possible.

[0067] Furthermore, according to this embodiment, the binding portion shape information 765 includes information on the two-dimensional shape of the binding machine 61 as viewed from the direction of approach between the intersection P and the binding machine 61. In other words, since the information being compared between the intersection point P and the binding machine 61 is both two-dimensional information, the amount of information can be reduced, and processing can be performed simply.

[0068] Furthermore, according to this embodiment, it is determined whether the intersection point P (reinforcement bar S) and the binding machine 61 can approach each other based on the area ratio occupied by the intersection point P (reinforcement bar S) in the determination area G (observation range) observed by the first camera 31. This allows for easy determination of whether the intersection P and the binding machine 61 can approach each other by appropriately setting a threshold. Furthermore, even if there is an obstacle that could hinder binding, for example, the ability to determine whether binding is possible can be appropriately determined by taking into account the influence of this obstacle.

[0069] Furthermore, according to this embodiment, it is determined whether the binding machine 61 can approach the intersection P in multiple insertion directions (insertion positions). This allows us to determine whether binding is possible in other insertion directions, even if it is determined that binding is not possible in one insertion direction.

[0070] Furthermore, according to this embodiment, the control unit 77 moves the binding machine 61 from the observation position (shooting position) of the first camera 31 toward the intersection P. This allows the intersection P and the binding machine 61 to be brought closer together.

[0071] Furthermore, according to this embodiment, the intersection P and the binding machine 61 may be brought closer together by having a predetermined movable range (allowable range) in a direction perpendicular to the direction connecting the intersection P and the binding machine 61. In other words, the approach to the intersection point P is not necessarily the shortest distance between the center of the strapping machine 61 and the center of the intersection point P. Instead, the strapping machine 61 may be positioned slightly offset in the direction connecting the curl guide 613 and the guide 614. That is, the position of the strapping machine 61 relative to the intersection point P may be shifted within an acceptable range.

[0072] Furthermore, according to this embodiment, the strapping machine 61 may be moved along a straight line connecting a predetermined position (point) on the strapping machine 61 and the center of the intersection point P. This allows the binding machine 61 to move along the shortest distance connecting its center position and the center of intersection point P.

[0073] Furthermore, according to this embodiment, the intersection point P and the binding machine 61 may be brought closer together while the pivot axis Zr (torsion axis) is parallel to the line connecting a predetermined position (point) on the binding machine 61 and the center of the intersection point P. This allows the binding machine 61 to be inserted with the pivot axis Zr perfectly perpendicular to the intersection point P, enabling strong binding. Furthermore, because the binding machine 61 has its narrowest outer shape along the pivot axis Zr, it is easier to approach the intersection point P.

[0074] Furthermore, according to this embodiment, if it is determined that the intersection P and the binding machine 61 cannot approach each other, the first camera 31 may change its observation position and observe the intersection P again. This will improve the system for determining whether or not it is permissible to approach.

[0075] Furthermore, according to this embodiment, the inner surface of the strapping machine 61 (curl guide 613, guide guide 614) is parallel (straight arm) to the direction of approach between the intersection P and the strapping machine 61. Therefore, when inserting the binding machine 61 into the intersection P, the binding machine 61 is less likely to get caught on reinforcing bars S, etc. Also, even if the position shifts due to the binding operation, the binding machine 61 (curl guide 613, guidance guide 614) is less likely to affect the object being bound.

[0076] [Differentiation] Although embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above. For example, a three-dimensional model of workpiece B may be generated based on information observed by the first camera 31, and the position of intersection point P may be detected from the three-dimensional model. In this case, the feasibility of subsequent bonding (approachability) may also be represented on the three-dimensional model. This eliminates the need to process pre-stored rebar arrangement models. In other words, if, for example, environmental conditions such as the amount of incident light prevent the acquisition of image data at the required resolution, or if the manufacturing precision and orientation differences of the actual rebar (such as ribs being placed on the top and bottom surfaces) are not accurately reflected in the rebar arrangement model, it may become difficult to make a judgment based on that rebar arrangement model. In this respect, using a simplified model based on captured images does not cause problems due to such minor differences in conditions.

[0077] Furthermore, in the bundling process of the above embodiment, the approachability determination in step S21 is performed based on the information observed (captured) by the first camera 31. However, the approachability determination may also be performed based on the information observed by the second camera 51. In other words, the observation unit according to the present invention includes a first camera 31 (first observation unit) capable of simultaneously observing multiple intersections P, and a second camera 51 (second observation unit) capable of observing a single intersection P. Furthermore, the observation unit according to the present invention only needs to be capable of observing the workpiece (object to be bound) in two dimensions, and the type of sensor is not particularly limited. For example, it may be a sensor using optical radar, active stereo, optical interferometry, lens focusing, etc., or it may be another sensor using magnetism, ultrasound, X-rays, etc.

[0078] Furthermore, in the above embodiment, the shooting area E1 (first region) and the binding area E2 (second region) are different. However, the shooting area E1 and the binding area E2 may partially overlap or may be a single unit (identical). In this case, the overall shooting unit 3 and the robot arm 4 are configured to move across a range that includes the shooting area E1 and the binding area E2.

[0079] Furthermore, in the above embodiment, the workpiece holder 2 moves the workpiece B in the X direction, but the workpiece B may also be moved or rotated in other directions. For example, if the workpiece holder 2 can rotate the workpiece B around a horizontal axis to invert its upper and lower surfaces, it can suitably accommodate workpiece B with double reinforcement arrangements on the upper and lower sides.

[0080] Furthermore, in the above embodiment, a workpiece B in which multiple reinforcing bars S are arranged three-dimensionally was exemplified as the object to be bound according to the present invention. However, the object to be bound according to the present invention only needs to have intersections P, and does not need to be a multiple reinforcing bar arranged three-dimensionally. Here, an object to be bound in which multiple reinforcing bars are arranged three-dimensionally means one in which multiple intersections are arranged three-dimensionally.

[0081] Alternatively, the robot arm 4 may be configured to select a binding device 6 having an insertion portion (a portion inserted between reinforcing bars S) of a size corresponding to the target intersection Pa. In this case, the robot arm 4 and the binding device 6 are configured to be detachable, and multiple binding devices 6 having insertion portions of different sizes are prepared. The control unit 77 then selects one binding device 6 from among the multiple binding devices 6 that is capable of binding the target intersection Pa to be bound. In this case, the multiple binding devices 6 may be arranged at predetermined positions within the movement range of the robot arm 4, and the exchange of binding devices 6 by the robot arm 4 may be automated.

[0082] Furthermore, in the above embodiment, an example of applying the present invention to a robot arm system utilizing a robot arm was described. However, the present invention can be suitably applied to binding methods other than the robot arm method, such as a workpiece transport method that transports workpieces, a gantry method that moves the device using a gantry, and a self-propelled method that moves the entire device, including the binding device, on the workpiece. However, the present invention is more preferably applicable to a system where the entire device is installed (fixed) indoors, for example, and the workpiece is moved, as in the above embodiment. In the case of a mobile body that moves freely, such as a self-propelled robot, or for outdoor work, applying the structure of the above embodiment may lead to problems such as an increased risk of collision with the information acquisition unit, distortion of the acquired signal (camera image) due to collisions, etc., an increase in the overall size of the device, and the need to waterproof the information acquisition unit.

[0083] Furthermore, details shown in the above embodiments can be modified as appropriate without departing from the spirit of the invention. [Explanation of Symbols]

[0084] 1. Binding system (binding device) 4. Robot arm (mobile part) 6 Binding device 7 Control device 31. Camera 1 (Observation Unit) 51. Second camera (observation unit) 61. Rebar tying machine (tying section) 76 Memory section 77 Control Unit (Determination Unit) 613 Curl Guide 614 Guidance Guide 761 Binding Program 762 Image Data 764 Reinforcement Bar Arrangement Model 765 Binding part shape information B Work G Judgment Area (Observation Range) P, P1, P2 intersection Pa Intersection S-shaped reinforcing bars S1 Main reinforcement S2 stirrup Zr rotation axis (torsion axis)

Claims

1. A binding section capable of binding three-dimensional objects including intersections, A movable part that allows the binding part and the object to be bound to move relative to each other, An observation unit for observing the bundled object in two dimensions, A determination unit determines whether the intersection and the binding portion can approach each other based on the information of the bound object observed by the observation unit, A binding device equipped with a binding mechanism.

2. The system includes a storage unit that pre-stores shape information of the aforementioned binding portion, The determination unit determines whether the intersection and the binding portion can approach each other based on the shape information of the binding portion stored in the storage unit and the information of the intersection observed by the observation unit. The binding device according to claim 1.

3. The shape information of the binding portion includes information on the two-dimensional shape of the binding portion as viewed from the direction of approach between the intersection and the binding portion. The binding device according to claim 2.

4. The determination unit determines whether the intersection and the binding unit can approach each other based on the area ratio occupied by the intersection within a predetermined observation range observed by the observation unit. The binding device according to claim 3.

5. The determination unit determines whether the binding portion can approach the intersection in multiple insertion directions. The binding device according to claim 4.

6. The system includes a movement control unit that controls the aforementioned movement unit, The movement control unit moves the binding portion from the observation position of the observation unit toward the intersection. The binding device according to claim 1.

7. The movement control unit has a predetermined movable range (allowable range) in a direction perpendicular to the direction connecting the intersection and the binding portion, and moves the intersection and the binding portion closer together. The binding device according to claim 6.

8. The movement control unit moves the binding portion along a straight line connecting a predetermined position in the binding portion and the center of the intersection point. The binding device according to claim 6.

9. The binding portion has a twisted shaft for binding the objects to be bound, The movement control unit moves the intersection and the binding portion closer together, with the torsion axis parallel to the line connecting the predetermined position in the binding portion and the center of the intersection. The binding device according to claim 6.

10. The observation unit includes a first observation unit capable of simultaneously observing multiple intersections and a second observation unit capable of observing a single intersection. The binding device according to claim 1.

11. If the determination unit determines that the intersection and the binding portion cannot approach each other, the observation unit changes its observation position and observes the intersection again. The binding device according to claim 10.

12. The inner surface of the binding portion is parallel to the direction of approach between the intersection and the binding portion. The binding device according to claim 1.

13. A computer controls a binding device comprising: a binding section capable of binding three-dimensional objects including intersections; a moving section capable of relatively moving the binding section and the objects to be bound; and an observation section for observing the objects to be bound in two dimensions. A determination unit determines whether the intersection and the binding part can approach each other based on the information of the bound object observed by the observation unit. A binding program that functions as such.

Images