Binding device and binding program

Abstract

The system is designed to determine whether or not the fastening portion can be inserted into the intersection. [Solution] The binding system 1 includes a binding machine 61 capable of binding workpieces B including an intersection P, a second camera 51 capable of observing workpieces B, and a control device 7. Based on the information observed by the second camera 51, the control device 7 calculates the distance between the intersection P and the back surface D of the intersection P, and determines whether or not the binding machine 61 can be inserted into the intersection P based on the calculated distance and the binding machine 61.

Description

Technical Field

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

Background Art

[0002] Conventionally, a bundling system is known 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 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 coordinates of the intersection are specified by a camera. Further, in the technique described in Patent Document 2, a Z-axis camera is provided separately from the XY-axis camera that obtains the two-dimensional coordinates of the intersection, and the Z-axis coordinate of the intersection is specified by the Z-axis camera.

Prior Art Documents

Patent Documents

[0003] [[ID=2�]]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, especially in the bundling of three-dimensional objects to be bundled, the distance between the intersection and the object on the back side thereof may change, and there is a risk that the bundling machine (bundling part) cannot be inserted to a depth at which the intersection can be bundled. Therefore, if it is possible to determine whether the bundling part can be inserted before bundling, it is useful for the safe and smooth progress of the bundling operation.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to suitably determine whether the bundling part can be inserted into the intersection.

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 objects including an intersection, An observation unit capable of observing the bundled object, A calculation unit calculates a first distance between the intersection and the back surface of the intersection based on the information observed by the observation unit, A determination unit determines whether or not the binding portion can be inserted into the intersection based on the first distance calculated by the calculation unit and the information of the binding portion, It is equipped with. [Effects of the Invention]

[0007] According to the present invention, it is possible to suitably determine whether or not a binding portion can be inserted into an intersection. [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 intersection image data acquired by the second camera. [Figure 9] This figure shows an example of image data to which height information has been added to the image data in Figure 8. [Figure 10] This diagram illustrates the insertion operation of the strapping machine, corresponding to the distance between the intersection and the back surface. [Figure 11]This is a diagram for explaining the insertion operation of the tying machine corresponding to the distance between the intersection point and the back surface. [Figure 12] This is a diagram for explaining the insertion operation of the tying machine corresponding to the distance between the intersection point and the back surface.

Embodiments 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 the intersection points where the plurality of reinforcing bars S intersect. The tying system 1 corresponds to an example of the tying apparatus 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 part 2, an overall photographing part 3, a robot arm 4, an individual photographing part 5, and a tying device 6. Among these, the workpiece holding part 2 is disposed inside the gantry 11 of the apparatus main body 10, and the overall photographing part 3, the robot arm 4, the individual photographing part 5, and the tying device 6 are mounted on the gantry 11. In the following description, each of the XYZ directions refers to the direction shown in FIG. 1. The XYZ directions are 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 gantry 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. Of the area inside the gantry 11, approximately half of one side in the X direction (the right side in FIG. 1) is the imaging area E1 where imaging by the overall imaging unit 3 is performed, and the other half (the left side in FIG. 1) is the bundling area E2 where the bundling operation by the robot arm 4 and the bundling device 6 is performed.

[0013] <Work holding unit> The work holding unit 2 holds the work B and moves the held work B between the imaging area E1 and the bundling area E2. The work B of the present embodiment is a reinforcing bar structure in which a plurality of main bars S1 and a plurality of stirrups S2 are three-dimensionally combined. Each of the main 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, 3 are arranged in parallel in the Y direction and 2 are arranged in parallel in the Z direction). Each of the stirrups S2 is arranged in a belt shape so as to go around the outside of the plurality of main 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 bars S1, stirrups S2) are bundled, each reinforcing bar S is held by a jig (not shown).

[0014] The work holding unit 2 includes a holding table 21 that holds the work B, a rail 22 that supports the holding table 21 movably, and a drive motor 23 that drives 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 the present embodiment is laid so that the holding table 21 (work B) can be moved 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 work 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 work holding unit 2 only needs to be able to move the holding table 21 (work B) from the imaging area E1 to the bundling area E2.

[0015] <Overall Photography Department> The overall imaging unit 3 images the entire workpiece B in the imaging area E1. Specifically, the overall imaging unit 3 includes a first camera 31 positioned above the imaging area E1 and a moving mechanism 32 that movably supports 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 stereo camera with compound eyes (e.g., 4 eyes), and 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.

[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 in 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 second camera 51 corresponds to an example of the observation unit according to the present invention. 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. The feed motor 615 drives the two wires W in the feeding direction F by forward rotation, allowing the wires W to be wound around the reinforcing bar S by the curl guide 613 and guide guide 614 located further ahead. That is, the wires W, which have been curled into an arc shape by the curl guide 613, are fed from the curl guide 613 towards the guide guide 614 and inserted into the guide guide 614. The feed motor 615 can also drive the two wires W in the reverse feeding direction R by reverse rotation, allowing the reinforcing bar S to be tightened with 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 its 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. Hereinafter, the tip portion of the binding machine 61 that is inserted into the intersection P (the portion that is inserted between the reinforcing bars S that make up the intersection P), including the curl guide 613 and the guide 614, will be referred to as the insertion portion 61T.

[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 unit 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 information 765 is information relating to the binding machine 61, and includes information about the insertion section 61T of the binding machine 61 that is inserted into the intersection P. The information about the insertion section 61T includes information about the insertion orientation into the intersection P in a plan view (for example, the 2 o'clock direction L1 described later; see Figure 8) and information about the insertion length Hm of the insertion section 61T inserted into the intersection P (see Figure 10).

[0042] 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 and position information of the intersection points P between the reinforcing bars S. In addition, it may also include information such as the spacing between reinforcing bars S in each XYZ direction, and if the reinforcing bars S are inclined, information on the angle. The rebar arrangement model 764 is an example of an intersection model according to the present invention, and only needs to include arrangement information for at least multiple intersection points P. 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.

[0043] 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.

[0044] [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 to 12 are diagrams illustrating the binding process. Of these, Figure 8 shows an example of image data of intersection P (target intersection Pa) acquired by the second camera 51, Figure 9 shows an example of image data in which height information of reinforcing bars S and other positions is added to Figure 8A, and Figures 10 to 12 are diagrams illustrating the insertion operation of the binding machine 61 corresponding to the distance between intersection P and its back surface D.

[0045] In the tying process, for example, multiple reinforcing bars S arranged in a grid pattern are tied together at the intersections P 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.

[0046] 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.

[0047] 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, the position of each intersection point P may be calculated based on the reinforcement bar arrangement model 764, which models the arrangement of multiple intersection points P. In this case, since an intersection point P is considered to be one that matches the shape (arrangement) of the reinforcement bar arrangement model 764, the calculation of its position is easier.

[0048] Next, 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).

[0049] 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 intersection P to be tied next from among several intersections P, excluding intersections P that have already been tied (or are recognized as such), based on, for example, a pre-set tying order. 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".

[0050] 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).

[0051] 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. The second camera 51 observes a predetermined observation range within the vicinity of the target intersection Pa. As a result, as shown in Figure 8, for example, image data 762b of the target intersection Pa is obtained 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.

[0052] 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).

[0053] 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. Furthermore, height information along the Z-direction is obtained here based on the image data. In this case, the control unit 77 may determine the binding direction based on the position and orientation of the binding device 6, which can insert its main part between the two reinforcing bars S. Furthermore, the control unit 77 may calculate the wire length (including the pull-back length) required for binding the target intersection Pa based on the diameter of the two reinforcing bars S that constitute the target intersection Pa, the intersection angle, etc.

[0054] Next, the control unit 77 performs an insertion feasibility determination to determine whether or not the binding machine 61 can be inserted into the target intersection Pa (step S8). Here, the feasibility of inserting (approaching) the binding machine 61 into the target intersection Pa is determined based on the image data acquired by the second camera 51 and the information of the binding machine 61. The following explanation describes the case where the target intersection Pa, composed of two reinforcing bars S along the X and Y directions, is the target of the determination. Therefore, in the following explanation, "higher side (upper side)" means the side closer to the second camera 51 in the direction of the second camera 51's shooting (foreground side), or the side closer to the binding machine 61 in the direction of the binding machine 61's insertion (foreground side), and "lower side (lower side)" means the opposite side.

[0055] Specifically, in determining whether insertion is possible, as shown in Figure 7, the control unit 77 first sets a predetermined measurement range G1 that includes the center C of the target intersection Pa in the image data acquired in step S6 (step S81; Figure 9). Figure 9 is an example of image data 762c in which height information of the reinforcing bars S and other positions, including the target intersection Pa, is added to the image data 762b in Figure 8.

[0056] Next, the control unit 77 determines the highest maximum height (reinforcement height) Hr among the reinforcing bars S within the measurement range G1 (step S82). In the example in Figure 9, the position where the reinforcement height Hr is located is approximately equal to the center C of the target intersection Pa.

[0057] Next, the control unit 77 determines the highest maximum height (back height) Hb of the back surface D of the reinforcing bar S within the measurement range G1 (step S83). Here, "back surface D" of the reinforcing bar S refers to the part other than the reinforcing bar S that is lower than the reinforcing bar S. In this step, the control unit 77 masks the intersection P portion of the measurement range G1 that includes the reinforcing bars S, creating a masked area G2, and then determines the height of the highest point among the remaining back surfaces D as the back surface height Hb.

[0058] Next, the control unit 77 compares the difference between the rebar height Hr and the back height Hb, "Hr-Hb", with the insertion length Hm of the binding machine 61 (step S84). Here, the control unit 77 first calculates the difference between the reinforcement height Hr and the back surface height Hb, "Hr-Hb," as the distance (first distance) between the target intersection Pa and the back surface D. The control unit 77 stores the calculated distance in the storage unit 76, associating it with the target intersection Pa. The control unit 77 then compares the calculated Hr-Hb with the insertion length Hm of the binding machine 61. The insertion length Hm of the binding machine 61 is the maximum length of the insertion section 61T of the binding machine 61 that is inserted into the intersection P, along the insertion direction. For example, it is the distance in the Z direction between the bottom surface 61f of the space surrounding the reinforcing bar S during insertion (between the curl guide 613 and the guide guide 614) and the tip (lower end) of the curl guide 613 (see Figure 10). The value of the insertion length Hm is pre-stored in the binding section information 765 of the storage unit 76.

[0059] In step S84, if the difference between the rebar height Hr and the back height Hb is greater than the insertion length Hm of the binding machine 61 (Hr-Hb>Hm), the control unit 77 determines that the target intersection Pa can be bound and inserts the insertion part 61T of the binding machine 61 to its innermost position, as shown in Figure 10 (step S85). Here, "larger" than the insertion length Hm means that the difference Hr-Hb is greater than the insertion length Hm by a predetermined amount including various errors and margins. This means that the difference Hr-Hb is definitely larger than the insertion length Hm, and the bundling machine 61 will not come into contact with the back surface D during insertion. Furthermore, "inserting to the deepest point" is not particularly limited, but it means inserting the insertion part 61T into the intersection P until, for example, the upper reinforcing bar S contacts (or is just about to contact) the bottom surface 61f of the insertion part 61T.

[0060] In step S84, if the difference between the rebar height Hr and the back height Hb is less than or equal to the insertion length Hm of the binding machine 61 (Hr-Hb≦Hm), the control unit 77 determines that the target intersection Pa can be bound, and inserts the insertion part 61T into the intersection P to an insertion depth where the insertion part 61T does not come into contact with the back surface D, as shown in Figure 11 (step S86). Here, the statement that the difference Hr-Hb is "less than or equal to" the insertion length Hm means that the difference Hr-Hb is equal to or smaller than the insertion length Hm. This means that when the insertion part 61T of the strapping machine 61 is inserted all the way in, there is a risk that the strapping machine 61 will come into contact with the back surface D. However, in this step, the insertion portion 61T may be determined to be uninsertable, and the binding of the target intersection Pa (step S9 described later) may be omitted. Also, as shown in Figure 12, if the difference Hr-Hb is close to the sum of the diameters of the multiple reinforcing bars S that form the intersection Pa (in the example in Figure 12, there are two reinforcing bars S, so Hr-Hb ≈ diameter of reinforcing bars S × 2), a wire path cannot be formed between the intersection Pa and the back surface D, so the binding of the target intersection Pa (step S9 described later) may be omitted, as insertion is deemed uninsertable.

[0061] In steps S85 and S86, the control unit 77 controls the movement of the robot arm 4 and, instead of the second camera 51, moves the bundling device 6 mounted on the end effector 43 closer to the target intersection Pa, and inserts the insertion part 61T of the bundling machine 61 into the target intersection Pa. In this case, the control unit 77 preferably aligns the relative position of the binding machine 61 and the workpiece B with the orientation in which the insertion distance of the binding machine 61 to the target intersection Pa is longer, among the insertion orientations of the binding machine 61 (insertion section 61T) in a plan view with respect to the target intersection Pa. In other words, the orientation of the insertion section 61T (curl guide 613 and guidance guide 614) in a plan view is set to the orientation with the longer insertion distance of the insertion section 61T (difference between difference Hr-Hb and insertion length Hm) among, for example, the 2 o'clock direction L1 and the 10 o'clock direction L2 (see Figure 8). In this case, candidate insertion orientations (2 o'clock direction L1, 10 o'clock direction L2) are stored in advance in the storage unit 76, and the control unit 77 selects one of these with the longer insertion distance of the insertion section 61T. At this time, the control unit 77 controls the movement of the binding machine 61 so that the reinforcing bars S that constitute the target intersection Pa do not come into contact with the binding machine 61.

[0062] Next, as shown in Figure 6, the control unit 77 operates the binding device 6 to bind the target intersection Pa with 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.

[0063] 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.

[0064] [Technical effects of this embodiment] As described above, according to this embodiment, the distance between the intersection point P and its back surface D (first distance) is calculated based on the information observed by the second camera 51, and it is determined whether or not the binding machine 61 can be inserted into the intersection point P based on this distance and the information from the binding machine 61. Therefore, it is possible to determine whether or not the binding machine 61 can be inserted into the intersection P. Consequently, the binding work can be performed safely without damaging the binding machine 61 by bringing it into contact with the back surface D.

[0065] Furthermore, according to this embodiment, the insertion distance of the strapping machine 61 in the insertion position of the strapping machine 61, which is stored in advance in the memory unit 76, is used to determine whether or not the strapping machine 61 can be inserted. In other words, by making a determination in the actual insertion position, it is possible to more reliably determine whether or not it is actually possible to fasten the item.

[0066] Furthermore, according to this embodiment, whether or not insertion is possible is determined based on the difference between the highest reinforcing bar height Hr among the reinforcing bars S and the highest back surface height Hb among the back surface D of the reinforcing bars S. In other words, in the insertion direction of the binding machine 61, whether or not insertion is possible is determined based on the distance between the closest position among the intersection points P and the closest position among the back surface D. This allows us to determine whether insertion is possible based on the shortest distance, using the front (upper) side of the insertion direction as a reference. However, the intersection points and back positions used to determine the distance for determining whether insertion is possible are not limited to the positions closest to the user in the insertion direction.

[0067] Furthermore, according to this embodiment, the relative position between the binding machine 61 and the workpiece B is controlled based on the information of the binding machine 61 stored in the memory unit 76 and the difference between the rebar height Hr and the back height Hb. This allows the angle between the intersection point P and the strapping machine 61 to be suitably changed for angles with greater depth. In other words, the angle of the strapping machine 61 can be adjusted to achieve an appropriate insertion angle with respect to the intersection point P.

[0068] Furthermore, according to this embodiment, the relative position of the binding machine 61 and the workpiece B is aligned with the direction in which the insertion distance of the binding machine 61 to the intersection P is longer. This allows the strapping machine 61 to be inserted in an insertion position that provides a longer insertion distance and minimizes the risk of contact between the strapping machine 61 and the back surface D.

[0069] Furthermore, according to this embodiment, the distance between each of the multiple intersection points P and the back surface D of the intersection point P is stored in the storage unit 76. Therefore, if there is an intersection P that is deemed unsuitable for binding, it is possible to determine, based on the data in the storage unit 76, whether or not the reason is due to the insertion depth.

[0070] Furthermore, according to this embodiment, based on the determination result regarding whether or not the binding machine 61 can be inserted into the intersection P, it is determined whether or not the intersection P can be bound with the binding machine 61. This allows for a favorable determination of whether or not the items can be tied together.

[0071] Furthermore, according to this embodiment, when Hr-Hb > Hm, the insertion portion 61T of the binding machine 61 is inserted to its deepest point, and when Hr-Hb ≤ Hm, the insertion portion 61T is inserted to a depth where it does not come into contact with the back surface D. In other words, the insertion distance of the binding machine 61 to the intersection P is controlled based on the calculation result of the distance between the intersection P and the back surface D. This allows the binding machine 61 to be moved to an appropriate height position according to the distance, and consequently enables strong binding tailored to the environment of each intersection P.

[0072] Furthermore, according to this embodiment, the intersection P and the binding machine 61 are controlled so as not to come into contact. This prevents damage to both the binding machine 61 and the workpiece B.

[0073] Furthermore, according to this embodiment, the position of an intersection point P is detected based on a rebar arrangement model 764 (intersection model) that models the arrangement of multiple intersection points P. This makes it easier to detect the position of intersection point P. Furthermore, because the position of each intersection point P is determined based on the overall arrangement, the position of each intersection point P can be detected appropriately even if the orientation of the workpiece B and the camera is slightly misaligned.

[0074] Furthermore, according to this embodiment, the second camera 51 observes a predetermined observation range within the vicinity of the intersection point P. This allows the observation range to be narrowed down to the necessary locations around intersection point P, enabling efficient determination of whether insertion is possible.

[0075] [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.

[0076] Furthermore, in the bundling process of the above embodiment, the insertion feasibility determination in step S8 is performed based on the information observed (captured) by the second camera 51. However, the insertion feasibility determination may also be performed based on the information observed by the first camera 31. In other words, the observation unit according to the present invention includes the first camera 31 and the second camera 51. Furthermore, the observation unit according to the present invention only needs to be capable of observing the workpiece (the object being bound), 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 that utilizes magnetism, ultrasound, X-rays, etc.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] Furthermore, details shown in the above embodiments can be modified as appropriate without departing from the spirit of the invention. [Explanation of symbols]

[0083] 1. Binding system (binding device) 7 Control device 31. Camera 1 (Observation Unit) 51. Second camera (observation unit) 61 Rebar tying machine (tying section) 61T Insertion section 76 Memory section 77 Control Unit (Calculation Unit, Determination Unit) 761 Binding Program Image data 762, 762b, 762c 764 Reinforcement bar arrangement model (intersection model) 765 Binding section information B Work (objects to be bound) D Back G1 Measurement range G2 Mask Area Hr Rebar height Hb Rear height L1 2 o'clock position (insertion position) L2 10 o'clock position (insertion position) P intersection Pa Intersection S-shaped reinforcing bars

Claims

1. A binding section capable of binding objects including an intersection, An observation unit capable of observing the bundled object, A calculation unit calculates a first distance between the intersection and the back surface of the intersection based on the information observed by the observation unit, A determination unit determines whether or not the binding portion can be inserted into the intersection based on the first distance calculated by the calculation unit and the information of the binding portion, A binding device equipped with a binding mechanism.

2. The system includes a storage unit that pre-stores the insertion position of the binding portion relative to the intersection, The calculation unit determines whether or not the fastening portion can be inserted based on the insertion distance of the fastening portion to the intersection in the insertion position. The binding device according to claim 1.

3. The calculation unit calculates the distance between the frontmost position of the intersections and the frontmost position of the back surface in the insertion direction of the binding portion as the first distance. The binding device according to claim 1.

4. It includes a storage unit that pre-stores information about the aforementioned binding portion. The binding device according to claim 1.

5. The system includes a control unit that controls the relative position between the binding unit and the object to be bound based on the information of the binding unit stored in the storage unit and the first distance calculated by the calculation unit. The binding device according to claim 4.

6. The control unit corresponds the relative position of the binding portion and the object to be bound to the orientation in which the insertion distance of the binding portion to the intersection is longer. The binding device according to claim 5.

7. It includes a storage unit that stores the distance between each of the multiple intersections and the back surface of that intersection, The binding device according to claim 1.

8. Based on the determination result regarding whether or not the fastening portion can be inserted into the intersection, the determination unit determines whether or not the intersection can be fastened with the fastening portion. The binding device according to claim 1.

9. The system includes a control unit that controls the relative position between the binding portion and the object to be bound, The control unit controls the insertion distance of the binding portion into the intersection based on the calculation result of the calculation unit. The binding device according to claim 1.

10. The control unit controls the intersection and the binding portion so that they do not come into contact. The binding device according to claim 9.

11. The system includes a recording unit that pre-records an intersection model which models the arrangement of multiple aforementioned intersections, The determination unit detects the position of the intersection based on the intersection model. The binding device according to claim 1.

12. The observation unit observes a predetermined observation range within the vicinity of the intersection. The binding device according to claim 1.

13. A computer controls a binding device that includes a binding section capable of binding objects including an intersection point, and an observation section capable of observing the objects to be bound. A calculation unit calculates a first distance between the intersection and the back surface of the intersection based on the information observed by the observation unit. A determination unit determines whether or not the binding portion can be inserted into the intersection based on the first distance calculated by the calculation unit and the information of the binding portion. A binding program that functions as such.

Images