Automated work system

Abstract

Monitor the work environment for automated tasks. [Solution] The dishwashing system comprises a work robot that transports multiple containers, a work table on which the containers are placed, a work control unit that controls the work robot, and a monitoring unit that monitors the work status. The monitoring unit determines that an abnormal condition is met when, in the normal area 176 set on the work table, a portion of the dishes contained in the containers is within the normal area 176, while the rest is outside the normal area 176.

Description

Technical Field

[0001] The present invention relates to automation of work, and in particular to a technique for preventing automatic work from being continued in an abnormal state.

Background Art

[0002] The food and beverage industry is a huge industry. It is said that the market size of the domestic restaurant industry alone amounts to 21 trillion yen. The food and beverage industry is a labor-intensive industry. Many restaurants are troubled by labor shortages. There are many simple tasks and heavy labor in the food and beverage industry. The working environment also tends to be harsh. There is a strong demand for work automation in the food and beverage industry.

[0003] There are various technical barriers to automation in the food and beverage industry. As an example, since the shapes and sizes of food materials are irregular, and tableware and cooking utensils are also diverse, there is a problem that handling by robots is difficult.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problem to be Solved by the Invention

[0005] In view of such problems, the present inventors have been studying "collaborative automation" in which humans and robots work cooperatively as a preliminary stage to full automation. In order to realize collaborative automation, it is necessary to prepare an environment where robots can work appropriately. Specifically, before the robot handles work objects (for example, tableware, containers, cooking utensils, etc.), those work objects must be properly arranged. However, imposing a new burden on humans to prepare the working environment for the robot puts the cart before the horse.

[0006] This invention was completed in view of the above-mentioned problems, and its main objective is to provide a technology for monitoring the work environment so that appropriate automated work can be performed. [Means for solving the problem]

[0007] An automated work system in one aspect of the present invention comprises a work machine that sequentially performs predetermined tasks on multiple objects, a placement surface on which the objects to be worked are arranged, a work control unit that controls the work machine, and a monitoring unit that monitors the work status. The monitoring unit determines that an abnormal condition is met when, within the normal area set on the placement surface, a portion of either the work machine or the object is within the normal area while the remainder extends outside the normal area. [Effects of the Invention]

[0008] According to the present invention, monitoring the work environment for automated work makes it easier to perform automated work appropriately. [Brief explanation of the drawing]

[0009] [Figure 1] This is a perspective view of the dishwashing system. [Figure 2] This is a hardware configuration diagram of a dishwashing system. [Figure 3] This is a schematic diagram illustrating the movement of a container. [Figure 4] This is a top view of the container in the second preparation area when it is being imaged. [Figure 5] This is a hardware configuration diagram of the cleaning control device. [Figure 6] This is a functional block diagram of the cleaning control device. [Figure 7] This is a schematic diagram illustrating the container retraction operation. [Figure 8] This is a schematic diagram illustrating the container pushing motion. [Figure 9] This is a flowchart showing the process for detecting an anomaly. [Figure 10] This is a top view showing the normal area being placed between the first preparation area and the second preparation area. [Modes for carrying out the invention]

[0010] Figure 1 is an external perspective view of the dishwashing system 200. The dishwashing system 200 (automated work system) is a system for washing various tableware such as plates, cups, chopsticks, and spoons. The dishwashing system 200 is installed in the kitchen of a relatively large restaurant. Below, as shown in Figure 1, the XYZ coordinate system is set with the left-right direction as the X direction, the front-back direction as the Y direction, and the up-down direction as the Z direction.

[0011] The dishwashing system 200 includes a washing control device 100, a work robot 102 (working machine), a pre-washer 104, a main washer 106, a first workbench 108, and a second workbench 110. In addition, the dishwashing system 200 is equipped with a camera and a group of sensors (described later). After eating and drinking, the dishes are stored in container 112 (object). Container 112 is a box-shaped tray capable of storing various types of dishes. The dishes are washed in two stages: "pre-washing" and "main washing." Pre-washing removes large pieces of dirt attached to the dishes. Pre-washing is performed by a pre-washing machine 104. For pre-washing, container 112 is placed in the pre-washing area 140 inside the pre-washing machine 104. The pre-washing machine 104 has a cover member 124 that can slide up and down (in the Z direction). When the cover member 124 is pulled down, container 112 in the pre-washing area 140 is sealed by the cover member 124. Pre-washing is performed after sealing.

[0012] In this washing process, hot water and detergent are sprayed onto the dishes to carefully remove any remaining dirt. This washing is performed by the washing machine 106. During this washing process, the container 112 is placed in the washing area 142 within the washing machine 106. The washing machine 106 also has a cover member 128 that can slide up and down, and when the cover member 128 is pulled down, the washing area 142 is sealed. After sealing, the washing is performed.

[0013] A multi-jointed work robot 102 is installed between the pre-washing machine 104 and the main washing machine 106. A hand member 126 (end effector) is attached to the tip of the work robot 102. The work robot 102 operates the container 112, the pre-washing machine 104, and the main washing machine 106. The washing control device 100 controls the work robot 102. The washing control device 100 is connected to the work robot 102 by a wireless or wired communication line. The washing control device 100 may be a general-purpose computer such as a desktop PC (Personal Computer), tablet PC, laptop PC, or smartphone, or it may be a dedicated computer for the dishwashing system 200.

[0014] The first workbench 108 is installed on the front side (positive Y-axis side) of the pre-washing machine 104. The container 112 before pre-washing is placed on the first workbench 108. The second workbench 110 is installed on the side side (positive X-axis side) of the main washing machine 106. The container 112 after main washing is placed on the second workbench 110. Sensors for detecting the position of the container 112 are installed on the first workbench 108 and the second workbench 110 (described later).

[0015] An operator places a container 112 storing tableware to be washed on a first work table 108 (arrangement surface). As will be described later in detail, the work robot 102 hooks the container 112 placed on the first work table 108 with a hand member 126 and pulls it toward the pre-washing area 140. After putting the container 112 into the pre-washing area 140, the work robot 102 hooks the handle 120 provided on the cover member 124 of the pre-washing machine 104 with the hand member 126, and pulls down the cover member 124. When the cover member 124 is pulled down, the container 112 is completely sealed inside the pre-washing machine 104. The pre-washing machine 104 performs pre-washing after sealing the container 112.

[0016] After completion of pre-washing, the work robot 102 pulls up the cover member 124 of the pre-washing machine 104. Subsequently, the work robot 102 slides the container 112 that has completed pre-washing to the main washing area 142. After pulling the container 112 into the main washing area 142, the work robot 102 hooks the handle 120 of the main washing machine 106 with the hand member 126 and pulls down the cover member 128. Thereby, the container 112 is completely sealed inside the main washing machine 106. The main washing machine 106 performs main washing after sealing the container 112.

[0017] After completion of main washing, the work robot 102 pulls up the cover member 128 and slides the container 112 to the second work table 110. The operator unloads the container 112 from the second work table 110 and takes out the washed tableware.

[0018] Figure 2 is a hardware configuration diagram of a dish washing system 200. In the dish washing system 200, the main washing machine 106, the pre-washing machine 104, the work robot 102, a console 150, a sensor 130, a camera 152, and a washing control device 100 are interconnected via a communication line 154.

[0019] The communication line 154 is configured as a wired communication line, a wireless communication line, or a combination thereof. The console 150 is installed next to the dishwashing system 200 and has buttons for on-site workers to instruct the work robot 102 to start (start and resume) and stop work. The camera 152 is installed directly above the first workbench 108 and images the first workbench 108. The camera 152 is used to check whether the containers 112 are properly placed (details below). The sensor 130 is used to determine the placement of the containers 112 on the first workbench 108 and the second workbench 110 (details below).

[0020] Figure 3 is a schematic diagram illustrating the movement of container 112. Figure 3 shows a top view of the dishwashing system 200 as seen from directly above. The first workbench 108 is configured with a first preparation area 156 and a second preparation area 158 (first area) as places to put containers 112. Similarly, the second workbench 110 is configured with a first storage area 160 and a second storage area 162 as places to put containers 112.

[0021] The worker places the container 112 before washing in the first preparation area 156. The work robot 102 moves the container 112 from the first preparation area 156 to the second preparation area 158, the pre-washing area 140 (second area), the main washing area 142, the first storage area 160, and the second storage area 162 in that order. The worker then removes the washed container 112 from the second storage area 162. In other words, the areas involved with the worker are the first preparation area 156 and the second storage area 162, while the areas involved with the work robot 102 are the second preparation area 158, the pre-washing area 140, the main washing area 142, and the first storage area 160. By separating the areas for the worker and the areas for the work robot 102, safe collaborative automated work is achieved.

[0022] Six sensors 130 (sensors 130A to 130E) are installed corresponding to the first preparation area 156, the second preparation area 158, the first storage area 160, and the second storage area 162. In this embodiment, the sensors 130 are infrared sensors. Sensors 130A to 130D are installed on the first workbench 108 and emit infrared light in the positive Y-axis direction. Sensors 130E and F are installed on the second workbench 110 and emit infrared light in the negative X-axis direction. Each sensor 130 detects whether a container 112 is placed in the direction of the emitted infrared light by detecting the reflected light of the emitted infrared light.

[0023] The worker first places the container 112 in the first preparation area 156. At this time, the sensor 130A, which is installed next to the first preparation area 156, detects that the container 112 has been placed in the first preparation area 156. The same applies to the other sensors 130. When the second preparation area 158 is empty and the container 112 is placed in the first preparation area 156, the work robot 102 pulls the container 112 from the first preparation area 156 to the second preparation area 158. Details of how the work robot 102 moves the container 112 will be described later in relation to Figures 7 and 8.

[0024] When the pre-washing area 140 is empty and the container 112 is placed in the second preparation area 158, the work robot 102 pulls the container 112 from the second preparation area 158 into the pre-washing area 140. The work robot 102 lowers the cover member 124 of the pre-washing machine 104 to seal the pre-washing area 140. After sealing, the pre-washing machine 104 starts pre-washing.

[0025] When the main cleaning area 142 is empty and the container 112 that has been pre-cleaned is placed in the pre-cleaning area 140, the work robot 102 moves the container 112 from the pre-cleaning area 140 to the main cleaning area 142. The work robot 102 lowers the cover member 128 of the main cleaning machine 106 to seal the main cleaning area 142. After sealing, the main cleaning machine 106 starts the main cleaning.

[0026] When the first storage area 160 is empty and the cleaned container 112 is placed in the main cleaning area 142, the work robot 102 moves the container 112 from the main cleaning area 142 to the first storage area 160. When the second storage area 162 is empty and the container 112 is placed in the first storage area 160, the work robot 102 moves the container 112 from the first storage area 160 to the second storage area 162. The worker receives the cleaned container 112 from the second storage area 162. As described above, the worker and the work robot 102 work together to automatically wash the dishes (containers 112) that are brought in one after another.

[0027] Figure 4 is a top view of the container 112 located in the second preparation area 158 when it is being imaged. A camera 152 is installed above the first workbench 108. The imaging area 164 includes the second preparation area 158. The second preparation area 158 is approximately the same size as the container 112. The normal area 176 (the area to be monitored) is set at approximately the same position and size as the second preparation area 158. When the container 112 is moved to the second preparation area 158, the camera 152 images the entire container 112. Since the top of the container 112 is open, the captured image shows all the dishes inside the container 112. The washing control device 100 determines whether the dishes are protruding from the normal area 176 set in the captured image, in other words, whether the dishes are protruding from the container 112.

[0028] In this context, "overhang" refers to a situation where a portion of a dish is within the normal area 176, but the rest is outside of it. The washing control device 100 determines that an abnormality exists when it detects any dish overhang (abnormal condition met). If the container 112 is moved from the second preparation area 158 to the pre-washing area 140 with dishes still overhanging, the overhanging dishes may fall out of the container 112. Alternatively, there is a concern that the overhanging dishes may collide with other components such as the work robot 102. By checking for overhanging dishes before transporting the container 112 from the second preparation area 158 to the pre-washing area 140, it becomes easier to safely continue automated work by the work robot 102.

[0029] In Figure 4, part of the plate 168 extends outside the normal area 176. Part of the chopsticks 170 also extends outside the normal area 176. Therefore, when the container 112 is moved, there is a possibility that the plate 168 and chopsticks 170 will fall out of the container 112. On the other hand, the plate 172 is entirely within the normal area 176 and does not extend beyond the container 112. In Figure 4, since two pieces of tableware (plate 168 and chopsticks 170) extend beyond the container 112, the washing control device 100 determines that there is an abnormality. When an abnormality occurs, the washing control device 100 stops the work robot 102 and warns the worker (described later).

[0030] Figure 5 is a hardware configuration diagram of the cleaning control device 100. The cleaning control device 100 includes a storage 312 as a non-volatile memory for storing computer programs, a volatile memory 304 for expanding programs and data, and a processor 300 (CPU: Central Processing Unit) which incorporates registers, arithmetic units, instruction decoders, etc. (not shown) and reads and executes programs from the memory 304. The processor 300 is connected to a relatively high-speed first bus 302. In addition to the memory 304, a NIC (Network Interface Card) is connected to the first bus 302. Other devices such as a GPU may also be connected to the first bus 302.

[0031] The first bus 302 is connected to the relatively slower second bus 310 via a bridge 308. In addition to the storage 312, output devices 316 such as a monitor or speakers are connected to the second bus 310. Input devices 314 such as a mouse or keyboard, and peripheral devices 318 such as a printer may also be connected to the second bus 310. It should be noted that the connection method between the first bus 302 and the second bus 310 shown in Figure 5 is just one example, and it will be understood by those skilled in the art that other connection methods or configurations including other buses may also be used.

[0032] Figure 6 is a functional block diagram of the cleaning control device 100. Each component of the cleaning control device 100 is realized by hardware including arithmetic units such as a CPU and various coprocessors, memory and storage devices, and wired or wireless communication lines connecting them, and software stored in the storage devices that supplies processing instructions to the arithmetic units. The computer program may consist of device drivers, an operating system, various application programs located at a higher layer, and libraries that provide common functions to these programs. The blocks described below represent functional units, not hardware units.

[0033] The cleaning control device 100 includes a user interface processing unit 180, a communication unit 196, a data processing unit 182, and a data storage unit 184. The user interface processing unit 180 accepts user input via input devices such as touch panels and is responsible for processing related to the user interface, such as displaying images and outputting sound. The communication unit 196 is responsible for communication processing with external devices such as the work robot 102. The data storage unit 184 stores various types of data. The data processing unit 182 executes various processes based on the data input from the user interface processing unit 180, the data received by the communication unit 196, and the data stored in the data storage unit 184. The data processing unit 182 also functions as an interface for the communication unit 196, the user interface processing unit 180, and the data storage unit 184.

[0034] The user interface processing unit 180 includes an input unit 186 and an output unit 188. The input unit 186 accepts various inputs from the user. The user can stop and start the work robot 102 not only from the console 150 but also from the input unit 186. The output unit 188 outputs various information to the user. In addition to displaying a warning to the user when an abnormality occurs, the output unit 188 also displays the captured image (see Figure 4) on the screen.

[0035] The data processing unit 182 includes a work control unit 190, a monitoring unit 192, and a cleaning processing unit 194. The work control unit 190 controls the work robot 102. Based on the information obtained from each sensor 130, the work control unit 190 determines the timing for moving the container 112. The monitoring unit 192 monitors the second preparation area 158 (normal area 176) with the camera 152 and determines whether there is any overhang, in other words, whether an abnormal condition has been met. The cleaning processing unit 194 controls the preliminary cleaning machine 104 and the main cleaning machine 106. Specifically, the cleaning processing unit 194 confirms that the container 112 has been sealed in the preliminary cleaning machine 104 before instructing the preliminary cleaning machine 104 to start cleaning. The cleaning processing unit 194 also confirms that the container 112 has been sealed in the main cleaning machine 106 before instructing the main cleaning machine 106 to start cleaning. Once the cleaning is complete, the preliminary cleaning machine 104 and the main cleaning machine 106 notify the cleaning control device 100 that cleaning is complete.

[0036] Figure 7 is a schematic diagram illustrating the retraction operation of container 112. In Figure 7, container 112a was placed in the first preparation area 156 (front side), and the worker pushed container 112a toward the second preparation area 158 (back side) with container 112b in order to place container 112b in the first preparation area 156. Because container 112b pushed container 112a, there is no gap between container 112a and container 112b.

[0037] The tip of the hand member 126 has a claw portion 204 with a folded surface. Also, an insertion hole 202 is formed on the lower surface of each container 112. The work control unit 190 first sets the longitudinal direction of the hand member 126 of the work robot 102 to the Y axis, and adjusts the height of the hand member 126 so that the claw portion 204 is inserted into the insertion hole 202 of the container 112a. Then, the work control unit 190 hooks the claw portion 204 into the insertion hole 202 (this state is also called "gripping" the container 112a).

[0038] Next, the work control unit 190 moves the hand member 126 in the negative Y-axis direction while the hand member 126 is still gripping the container 112a (hereinafter referred to as the "retraction operation"). When the container 112a is retracted, a strong load is applied to the insertion hole 202 and the claw portion 204. The purpose of the retraction operation by the work robot 102 is to create a sufficient gap between the container 112a and the container 112b.

[0039] Figure 8 is a schematic diagram illustrating the pushing operation of container 112. The retraction operation creates a gap between container 112a and container 112b. After moving container 112a by a predetermined amount due to the retraction operation, the work control unit 190 detaches the hand member 126 from the insertion hole 202 and sets the longitudinal direction of the hand member 126 to the X-axis direction.

[0040] A relatively large pressing surface 206 is formed on the hand member 126. The work control unit 190 controls the work robot 102 to insert the hand member 126 between containers 112a and 112b, and bring the pressing surface 206 into contact with the side surface of container 112a. Next, with the pressing surface 206 in contact with the side surface of container 112a, the work control unit 190 moves the hand member 126 in the negative Y-axis direction (hereinafter referred to as the "pushing operation").

[0041] The pushing motion moves container 112a to the second preparation area 158. More specifically, the pushing motion is continued until sensors 130B and 130C detect container 112a, thereby aligning container 112a precisely with the second preparation area 158. During the pushing motion, the entire pressing surface 206 supports the weight of container 112, thus reducing the load on the hand member 126 and container 112 compared to the retraction motion. The purpose of the relatively strenuous retraction motion is to create a gap between container 112a and container 112b. After creating the gap, container 112a is moved a considerable distance by a relatively less strenuous pushing operation.

[0042] The sliding movement of the container 112 from the second preparation area 158 to the pre-washing area 140 is also achieved by a combination of pulling and pushing operations. The same applies to the sliding movement of the container 112 beyond the pre-washing area 140.

[0043] Figure 9 is a flowchart showing the processing steps for anomaly detection. The process shown in Figure 9 is executed when the container 112 is placed in the second preparation area 158. In this embodiment, an abnormality determination is performed based on whether or not there are dishes in the container 112 that are overflowing from the normal area 176, or dishes that are unsuitable for being put into the dishwasher.

[0044] Camera 152 captures an image of container 112 from directly above when it is placed in the second preparation area 158 (S10). The monitoring unit 192 identifies the position and shape of each dish from the captured image. If any of the dishes has unsuitable characteristics (Y in S12), the monitoring unit 192 stops the work robot 102 and notifies the worker of a warning (S22).

[0045] In this context, tableware with "unsuitable characteristics" (hereinafter referred to as "unsuitable tableware") refers to, for example, tableware that is not compatible with dishwashers, tableware that is cracked or chipped, or tableware that has too much leftover food on it to be placed in the pre-washer 104. The monitoring unit 192 determines the presence or absence of unsuitable tableware by analyzing the captured images. For example, the monitoring unit 192 detects lacquerware, ceramics, and silverware that are not compatible with dishwashers as unsuitable tableware through image recognition. In addition, the monitoring unit 192 determines that tableware is unsuitable tableware if it contains foreign objects (objects other than tableware) of a predetermined size or larger inside the tableware identified in the captured image.

[0046] Warning notifications are specifically issued by illuminating a lamp installed near the dishwashing system 200, outputting a warning sound from a speaker, or sending an email notification to a remote administrator. When the work robot 102 stops, the operator checks the container 112, removes the unsuitable dishes, and then restarts the work robot 102. The operator instructs the robot to restart from the console 150 or the washing control device 100.

[0047] If no non-suitable tableware is included (N in S12), the monitoring unit 192 determines whether any tableware is sticking out (S14). If there is no non-suitable tableware (N in S12) and no tableware is sticking out (Y in S14), the work control unit 190 moves the container 112 from the second preparation area 158 to the pre-washing area 140.

[0048] When an overhang is detected (N in S14) and the work robot 102 has not yet performed a "correction attempt" to eliminate the overhang (N in S18), the work control unit 190 performs a correction attempt by placing the hand member 126 of the work robot 102 against the side of the overhanging dish and moving the dish slightly inside the container 112 (S20). After the correction attempt and subsequent imaging (S24), the process returns to S14.

[0049] The monitoring unit 192 checks the captured image after the correction trial. If the overflow is eliminated by the correction trial (Y in S14), the work control unit 190 moves the container 112 to the pre-washing area 140 (S16). If the overflow is not eliminated even after the correction trial (N in S14, Y in S18), the work robot 102 stops and a warning notification is issued (S22).

[0050] [summary] The dishwashing system 200 has been described above based on the embodiments. According to this embodiment, it is possible to prevent problems such as dishes falling out of the container 112 before the work robot 102 moves the container 112 to the pre-washing area 140. The work robot 102 is also automatically stopped when unsuitable dishes are detected. This prevents problems caused by pre-washing unsuitable dishes. The worker who receives the warning notification checks the status of the container 112 and then has the work robot 102 resume work. The monitoring unit 192 may also determine whether the container 112 contains foreign objects (objects other than dishes, such as electronic devices or paper) that should not be put into the dishwasher, not just unsuitable dishes.

[0051] When an overflow is detected, the cleaning control device 100 performs a corrective attempt. If the corrective attempt is successful, the work robot 102 can continue working without stopping, making it easier to maintain processing efficiency. In this embodiment, the maximum number of corrective attempts is one, but any upper limit of two or more may be set.

[0052] It should be noted that the present invention is not limited to the embodiments and modifications described above, and the components can be modified and implemented without departing from the spirit of the invention. Various inventions may be formed by appropriately combining the multiple components disclosed in the embodiments and modifications described above. In addition, some components may be deleted from all the components shown in the embodiments and modifications described above.

[0053] [Differentiation] If the first workbench 108 is not used, the placement areas such as the second preparation area 158 may be set on the floor.

[0054] The normal area 176 may be the same size as the container 112, or it may be set to be smaller than the container 112. Alternatively, the normal area 176 may be set to be slightly larger than the container 112. The monitoring unit 192 may arbitrarily change the size of the normal area 176 according to instructions from the user. When the normal area 176 is relatively small, overflows are more easily detected, making it easier to prevent failures. On the other hand, when the normal area 176 is relatively large, a small overflow of dishes from the container 112 is tolerated, making it easier to continue automated work.

[0055] In this embodiment, the description focuses on automated work performed by a work robot 102, but the present invention can also be applied to various stationary machines. For example, a camera 152 may be installed inside the pre-washing machine 104, and an imaging area 164 and a normal area 176 may be set in the pre-washing area 140. The monitoring unit 192 determines that an abnormal condition has been met when an overflow is detected in the normal area 176 of the pre-washing area 140. The same applies to the main washing machine 106. Furthermore, if an ultraviolet irradiation device is used to sterilize the dishes after washing, an imaging area 164 and a normal area 176 may be set inside the ultraviolet irradiation device.

[0056] The abnormality detection method shown in this embodiment can be applied to situations other than dishwashing. For example, suppose containers are transported by a belt conveyor and food is placed into these containers by a work robot. The normal range 176 is set to be the range in which the work robot's hand member can work normally (normal range of motion). The monitoring unit 192 may determine that there is an abnormality when the container is outside the normal range 176, that is, when the container is outside the range in which the work robot can work. By detecting containers that are in a position where food cannot be placed, it is possible to prevent containers that are not properly filled with food from being transported to subsequent processes.

[0057] The abnormality detection method described in this embodiment can be applied to situations other than the food and beverage industry. For example, in a factory setting where a robot assembles products, a normal area 176 can be set as the range in which the robot can perform its work normally, and an abnormality can be detected when the product or tool being worked on extends beyond this normal area 176.

[0058] The monitoring unit 192 may detect not only overhangs but also "unnatural tilting of dishes" as a non-conforming condition. Dishes may not be properly secured to the support members inside the container 112, causing them to tilt unnaturally. In this case, when the container 112 is moved, the dishes may move around a lot inside the container 112, potentially damaging other dishes. The monitoring unit 192 may determine that an abnormality exists when predetermined conditions are met regarding the angle of the dishes or the positional relationship between the dishes and the support members.

[0059] The monitoring unit 192 determines that a dish is overflowing (abnormal) when part of the dish is within the normal area 176 and the rest is outside the normal area 176. As a variation, the monitoring unit 192 may also determine that a dish is overflowing (abnormal) when there is a foreign object (an object other than the first workbench 108) outside the normal area 176 in the imaging area 164, in other words, when the entire foreign object is outside the normal area 176, rather than just overflowing. For example, the monitoring unit 192 may determine that a dish is overflowing when the dish is placed outside the container 112 on the first workbench 108.

[0060] The washing control device 100 may be capable of setting multiple work modes. For example, an efficiency-priority mode (high-speed mode) and a normal mode may be set as work modes. In the efficiency-priority mode, the normal area 176 is set to be larger than in the normal mode. A larger normal area 176 makes it less likely for abnormal conditions to occur, thus increasing the processing efficiency of dishwashing. Alternatively, a safety mode and a normal mode may be set as work modes. In the safety mode, by making the normal area 176 smaller than in the normal mode, the possibility of malfunctions occurring during automated operation can be reduced. In this way, the size of the normal area 176 may be changed according to the multiple work modes. Not only the size of the normal area 176, but also its position and shape may be changed. By changing the normal area 176 according to the work mode, the balance between monitoring capability and processing efficiency can be flexibly changed.

[0061] If multiple types of containers 112 are present, the monitoring unit 192 may change the normal area 176 according to the shape of the containers 112. For example, when a rectangular container 112 is set in the second preparation area 158, the monitoring unit 192 sets a rectangular normal area 176 that encompasses the container 112. When a circular container 112 is set in the second preparation area 158, the monitoring unit 192 may set a circular normal area 176 that encompasses the container 112. The monitoring unit 192 can identify the shape of the container 112 by analyzing the captured image of the container 112 and set the normal area 176 according to the identified shape.

[0062] Figure 10 is a top view showing the normal area 176 being placed between the first preparation area 156 and the second preparation area 158. As explained in relation to Figure 8, the work robot 102 creates a gap between container 112a in the second preparation area 158 and container 112b in the first preparation area 156, and then inserts the hand member 126 into the gap to push in container 112a. However, if the worker immediately moves container 112b towards container 112a after the gap has been created by the retraction operation of container 112a, the gap for the pushing operation will be blocked.

[0063] To solve this problem, an imaging area 164 and a normal area 176 may also be set between the second preparation area 158 and the first preparation area 156. The monitoring unit 192 determines that there is an abnormality if a part of the container 112b enters the normal area 176 within the time between the completion of the retraction operation of the container 112a in the second preparation area 158 and the start of the pushing operation, and stops the work robot 102. The monitoring unit 192 also notifies the worker by voice or other means that the location of the container 112b is too close to the second preparation area 158 and that the worker should change its location. This control method prevents the work robot 102 from being unable to continue work because the worker has placed the container 112b in an inappropriate location.

[0064] In addition, the monitoring unit 192 may set a normal area 176 in the portion where the cover member 124 contacts the pre-washing area 140 (the boundary area between the pre-washing machine 104 and the first workbench 108). The monitoring unit 192 determines that there is an abnormality when the container 112 or the dishes are included in the normal area 176. More precisely, the monitoring unit 192 determines that there is an abnormality when the container 112 is moved toward the pre-washing area 140, and after the container 112 stops, the container 112 or the dishes are included in the normal area 176 (i.e., when it is determined that part of the container or dishes is in the pre-washing area 140, but part of it is outside the pre-washing area 140). With this control method, it is possible to prevent the end of the cover member 124 from contacting the container 112 or the dishes when the work robot 102 lowers the cover member 124. The same applies to the cover member 128 of the washing machine 106.

[0065] The monitoring unit 192 may determine which part of the container 112 is located within the normal area 176 (the portion where the cover member 124 contacts the pre-cleaning area 140: boundary area) described above. If the majority of the container 112 is within the pre-cleaning area 140, and the rear end portion of the container 112 (the portion on the positive X-axis side) is within the normal area 176, the monitoring unit 192 will determine that the container 112 is not correctly positioned within the pre-cleaning area 140 and that this is an abnormality. The monitoring unit 192 may also determine that the rear end of the container 112 is an abnormality if it remains within the normal area 176 for a predetermined time or longer, for example, 3 seconds or more.

[0066] When the front end portion (the portion on the negative X-axis side) or the central portion of container 112 is within the normal area 176, container 112 may be in motion. In this case, the work control unit 190 will not close the pre-washing machine 104 until container 112 is no longer visible in the normal area 176. The monitoring unit 192 may determine that there is an abnormality if the front end or central portion of container 112 remains within the normal area 176 for a predetermined period of time or longer, for example, 3 seconds or more. The work control unit 190 may close the pre-washing machine 104 only if the state in which container 112 is not visible in the normal area 176 continues for a predetermined period of time or longer.

[0067] The system may also detect any overhangs in the work robot 102, which is the main worker, rather than in the work object such as the container 112. The monitoring unit 192 sets a normal area 176 within the range in which the work robot 102 can work. The monitoring unit 192 determines whether any part of the work robot 102 is overhanging the normal area 176.

[0068] One possible reason why the work robot 102 extends beyond the normal area 176 is that the hand member 126 is not properly fixed to the work robot 102 body, causing the hand member 126 to extend outside the normal area 176. Furthermore, if the work robot 102 has replaceable parts, it's possible that a part different from the intended specification has been mistakenly installed. For example, the work robot 102 of the dishwashing system 200 should have a medium-sized hand member 126a installed, but a large-sized hand member 126b might have been mistakenly installed instead. In such cases, the tip of the work robot 102 extends beyond the intended working range (normal area 176), allowing for the detection of an incorrect assembly of the work robot 102.

[0069] The operating modes may be set to either an energy-saving mode or a normal mode. In energy-saving mode, power consumption is reduced by setting a smaller working range or working speed for the robot 102. In this case, the monitoring unit 192 only needs to set the normal range 176 smaller than in normal mode. Alternatively, in energy-saving mode, the operating range of the robot 102 may not be changed, but the normal range 176 may be set larger than in normal mode to save power used for corrective attempts and warnings.

[0070] Food residue adheres to the first workbench 108. There is a possibility that the monitoring unit 192 may mistakenly detect the residue on the first workbench 108 as tableware protruding from the container 112. To prevent such misdetection, the monitoring unit 192 acquires an image P1 targeting the imaging area 164 when the container 112 is not installed. Next, it acquires an image P2 when the container 112 is installed. The monitoring unit 192 compares the images P1 and P2 and sets the parts common to both images but different from the first workbench 108 (the residue on the first workbench 108) as parts to be excluded from the judgment. This control method reduces the risk of misidentifying a foreign part on the first workbench 108 that is unrelated to the container 112 as tableware. The data processing unit 182 may include a learning unit (not shown). The learning unit may improve the accuracy of overflow detection by associating previously collected images (especially those suspected of overflow) with the results of confirming whether or not the overflowing object was actually tableware, and then using machine learning (supervised learning).

[0071] In addition, the normal area 176 to be monitored may be set at any location on the first workbench 108, the preliminary washing machine 104, the main washing machine 106, or the second workbench 110.

[0072] Processing efficiency may be improved by increasing the movement speed of the container 112 during the pushing operation, which places less load on the work control unit 190 and the hand member 126, compared to the pulling operation, which places a load on the hand member 126. Alternatively, the shaking of the dishes inside the container 112 may be suppressed by performing the pushing operation, which moves the container 112 a large distance, at a lower speed compared to the pulling operation, which moves the container 112 only a little to create a gap. [Explanation of symbols]

[0073] 100 Washing control device, 102 Work robot, 104 Pre-washing machine, 106 Main washing machine, 108 First workbench, 110 Second workbench, 112 Container, 112a Container, 112b Container, 120 Handle, 124 Cover member, 126 Hand member, 126a Hand member, 126b Hand member, 128 Cover member, 130 Sensor, 140 Pre-washing area, 142 Main washing area, 150 Console, 152 Camera, 154 Communication line, 156 First preparation area, 158 Second preparation area, 160 First storage area, 162 Second storage area, 164 Imaging area, 168 Plate, 170 Chopsticks, 172 Plate, 176 Normal area, 180 User interface processing unit, 182 Data processing unit, 184 Data storage unit, 186 Input unit, 188 Output unit, 190 Work control unit, 192 Monitoring unit, 194 Cleaning unit, 196 Communication unit, 200 Dishwashing system, 202 Insertion hole, 204 Claw unit, 206 Pressing surface, 300 Processor, 302 First bus, 304 Memory, 308 Bridge, 310 Second bus, 312 Storage, 314 Input device, 316 Output device, 318 Peripheral device

Claims

1. A machine that sequentially performs predetermined tasks on multiple objects, The placement surface on which the object to be worked on is placed, A work control unit that controls the aforementioned work machine, It includes a monitoring unit for monitoring the work status, The monitoring unit is an automated work system that determines that an abnormal condition is met when, within the normal area set on the placement surface, a part of either the work machine or the object is within the normal area and the remainder is outside the normal area.

2. The aforementioned arrangement surface is provided with a first region and a second region. The normal region is set to the first region, The automated work system according to claim 1, wherein the work machine moves an object placed in the first area to the second area, provided that the abnormal condition is not met.

3. The automated work system according to claim 1, wherein the monitoring unit, when the abnormal condition is met, performs at least one of the following actions: generate an alarm or stop the work machine.

4. The automated work system according to claim 1, wherein the monitoring unit further determines that the abnormal condition is met when a part of the object is in a predetermined non-conforming state or has predetermined non-conforming characteristics.

5. The automated work system according to claim 1, wherein when the work control unit detects that the object has deviated from the normal area, the work machine moves the deviated portion of the object back into the normal area.

6. In the aforementioned work control unit, one of several work modes is set. The automated work system according to claim 1, wherein the monitoring unit changes the shape of the normal area according to the work mode.

7. The automated work system according to claim 1, wherein if a non-specific portion different from the arrangement surface is included outside the normal area, the monitoring unit determines from the captured image of the non-specific portion whether the non-specific portion is part of the object or a foreign object different from the object, and determines that the abnormal condition is not met if the object is not included in the non-specific portion.

8. The aforementioned work machine moves the tray, which contains one or more dishes as the object, from the first area to the second area. The second area is an area where one or more dishes stored in the tray are washed. The first region is the region on which the tray is temporarily placed before washing. The automatic work system according to claim 1, wherein the normal area is set to the first area.

Images