Position Deviation Calculation Device and Position Deviation Calculation Method

Abstract

To reduce the number of adjustment work man-hours required to adjust installation position posture errors (positional deviations) on an actual machine with respect to ideal values on design when overhauling a facility in a production line.SOLUTION: A positional deviation calculating apparatus has an arithmetic operation unit and a memory unit. The memory unit holds design information on a facility, work objects, and their arrangements. The arithmetic operation unit is configured to: extract contact portions with the work objects of the facility based on the design information; extract one or more positioning elements each corresponding to one of predetermined shapes from the contact portions; calculate a positioning direction of each positioning element based on the shape of each positioning element; calculate a positional deviation amount in the positioning direction of each positioning element of an actual facility with respect to a position of each positioning element specified by the design information based on a measurement result of the actual facility; and calculate a positional deviation direction and a positional deviation amount of the facility based on the measured positional deviation amount in the positioning direction of each positioning element.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a technique for calculating misalignment of equipment and the like in a manufacturing line.

Background Art

[0002] In the manufacturing industry, in order to promptly respond to production environment changes such as the spread of diseases and the occurrence of natural disasters, short-term repairs of equipment within the manufacturing line are required. There is an installation position error (misalignment) of the actual machine with respect to the ideal value in the design of the equipment. If the manufacturing line is operated without adjusting the misalignment of the equipment, the workpieces arranged and worked on within the equipment will also be misaligned, leading to problems such as a decline in work quality. Therefore, it becomes an issue that the man-hours for adjusting the misalignment of the equipment are required each time the equipment is repaired.

[0003] To adjust the misalignment of the equipment, it is necessary to extract the positioning elements of the equipment that determine the arrangement of the workpieces from the design information of the equipment, measure the misalignment of the extracted positioning elements with the actual machine, and determine the adjustment content. In order to automate these adjustment operations and reduce the adjustment man-hours, in order to automatically extract the positioning elements of the equipment from design information such as 3D-CAD data, it is necessary to extract the contact portions between the equipment and the workpieces and identify the positioning elements by analyzing the shapes of the contact portions.

[0004] As a method for extracting the contact portions between components from design information such as 3D-CAD data, there is a technique described in Japanese Patent Application Laid-Open No. 2007-316032 (Patent Document 1). This publication describes, "an extraction unit that extracts a contact surface where the end faces of two components are in contact with each other from the three-dimensional design data of a structure composed of a plurality of components, a contact state setting unit that sets the contact state of the contact surface, a holding unit that preliminarily holds heat resistance information for obtaining the thermal resistance of the contact surface according to the contact state of the contact surface, and a thermal conductivity calculation unit that calculates the thermal conductivity of the contact surface based on the heat resistance information corresponding to the contact state of the contact surface set by the contact state setting unit and held in this holding unit, and a generation unit that generates analysis data including the thermal conductivity calculated by this thermal conductivity calculation unit."

Prior Art Documents

Patent Document

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] The method of Patent Document 1 extracts the contact parts between components from the design information of a structure composed of a plurality of components and calculates the area of the contact parts, but does not analyze the shape of the contact parts and cannot identify the positioning elements. This is because the positioning direction of the positioning elements varies depending on the shape of the contact part between the equipment and the workpiece, and thus shape analysis of the contact part is required for calculating the misalignment.

[0007] Therefore, an object of the present invention is to provide a technique for reducing the man-hours for adjusting the misalignment of equipment by automatically calculating the misalignment of the positioning elements.

Means for Solving the Problems

[0008] In order to solve at least one of the above problems, for example, the configuration described in the claims is adopted. This application includes a plurality of means for solving the above problems. As an example, it is a misalignment calculation device having an arithmetic unit, a storage unit, and a measurement unit. The storage unit holds equipment design information indicating the dimensions and shape of the components of the equipment, work object design information indicating the dimensions and shape of the work object by the equipment, and arrangement design information indicating the arrangement of the equipment and the work object. The arithmetic unit extracts the contact portion of the equipment with the work object based on the equipment design information, the work object design information, and the arrangement design information, extracts one or more positioning elements from the contact portion, each of which corresponds to a predetermined shape, calculates the positioning direction of each positioning element based on the shape of each positioning element, the measurement unit measures the misalignment amount of the positioning direction of each positioning element of the actual equipment with respect to the position of each positioning element specified by the equipment design information, the work object design information, and the arrangement design information, and the arithmetic unit calculates the misalignment direction and misalignment amount of the equipment based on the measured misalignment amount of the positioning direction of each positioning element.

Effect of the Invention

[0009] According to one aspect of the present invention, positioning elements can be extracted from design information, the misalignment of the equipment can be automatically calculated, and the man-hours for adjusting the misalignment of the equipment can be reduced.

[0010] Problems, configurations, and effects other than those described above will be clarified by the description of the following embodiments.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2A

Figure 2B

Figure 3A

Figure 3B

Figure 4A

Figure 4B

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Mode for Carrying Out the Invention

[0012] Hereinafter, the position deviation calculation device according to the present invention will be described based on embodiments with reference to the drawings. In the examples described below, the same or similar configurations or functions are denoted by the same reference numerals, and redundant descriptions are omitted.

Example

[0013] FIG. 1 is a block diagram showing an example of the schematic configuration of the position deviation calculation device in Example 1 of the present invention.

[0014] As shown in FIG. 1, the position deviation calculation device 100 includes an input unit 110, a storage unit 111, an arithmetic unit 112, a positioning element position deviation measurement unit 200, an output unit 210, and a display unit 220.

[0015] The input unit 110 inputs information to be stored in the storage unit 111. The storage unit 111 includes a facility design information storage unit 120 for storing input information, a work design information storage unit 130, an arrangement design information storage unit 140, a positioning element displacement information storage unit 150 for storing output information, and a facility displacement information storage unit 160. The facility design information storage unit 120 stores facility design information such as the dimensions and shapes of the components of the facility. The work design information storage unit 130 stores work design information such as the dimensions and shapes of the workpieces arranged in the facility and on which predetermined operations are performed. The arrangement design information storage unit 140 stores arrangement design information indicating the arrangement of the workpieces in the facility. The positioning element displacement information storage unit 150 stores the displacement of the positioning elements. The facility displacement information storage unit 160 stores the displacement of the facility.

[0016] The calculation unit 112 includes a positioning element extraction unit 170, a positioning direction calculation unit 180, and a facility displacement calculation unit 190. These may be realized, for example, by the calculation unit 112 executing a program stored in the storage unit 111. The positioning element extraction unit 170 extracts, using the information stored in the storage unit 111, positioning elements that are shape elements having a function of determining the arrangement of the workpieces by coming into contact with the workpieces among the shape elements of the facility. The positioning direction calculation unit 180 calculates the positioning direction of the extracted positioning elements. The facility displacement calculation unit 190 calculates the displacement of the positioning elements measured on the actual machine and calculates the facility displacement.

[0017] The positioning element displacement measurement unit 200 measures, on the actual machine, the displacement of the positioning elements required when the facility displacement calculation unit 190 calculates the facility displacement. For example, the positioning element displacement measurement unit 200 may be realized by a sensor for measuring the facility and the workpieces and a function of the calculation unit 112 that processes the data obtained from the sensor to calculate the displacement amount. The sensor may be, for example, at least any one of an optical camera for photographing the facility and the workpieces, a distance measuring sensor for measuring the distance to the facility and the workpieces, or other types of sensors.

[0018] The output unit 210 outputs the positioning element position deviation and the facility position deviation calculated by the calculation unit 112, and stores them in the positioning element position deviation information storage unit 150 and the facility position deviation information storage unit 160. The display unit 220 displays the positioning element position deviation and the facility position deviation stored by the output unit 210 in the positioning element position deviation information storage unit 150 and the facility position deviation information storage unit 160.

[0019] FIG. 2A is an explanatory diagram showing an example of the facility design information stored in the facility design information storage unit 120 in Embodiment 1 of the present invention.

[0020] The facility design information table 121 includes an ID column 122, a placement position and orientation column 123, and a shape column 124.

[0021] In the ID column 122, numbers for identifying the components constituting the facility are stored.

[0022] In the placement position and orientation column 123, information representing the placement position and orientation of each component is stored.

[0023] In the shape column 124, polygon mesh information representing the shape of each component is stored. For example, the shape column 124 includes a face number column 125, a vertex number column 126, and a vertex coordinate column 127.

[0024] In the face number column 125, numbers for identifying the faces constituting the polygon mesh are stored.

[0025] In the vertex number column 126, numbers for identifying the three vertices constituting each face are stored.

[0026] In the vertex coordinate column 127, information representing the coordinates of each vertex is stored.

[0027] FIG. 2B is an explanatory diagram showing an example of the facility drawn based on the facility design information in Embodiment 1 of the present invention.

[0028] The figure 128 illustrated in FIG. 2B is drawn based on the facility design information for a part including at least one positioning element of the facility. In the example of FIG. 2B, a part including a columnar positioning pin and a columnar positioning pin having a bottom surface with a shape other than a circle (for example, a so-called diamond pin having a bottom surface with an angular shape) of the facility is drawn. In this case, for example, at least a part of the side surface of each positioning pin and at least a part of the upper surface of the base on which the positioning pin is installed serve as positioning elements.

[0029] In this embodiment, the ID, arrangement position and orientation, and shape of the components constituting the facility are described as the facility design information, but information may be added to and deleted from the facility design information as necessary. This embodiment does not limit the information to be described as the facility design information.

[0030] FIG. 3A is an explanatory diagram showing an example of the workpiece design information stored in the workpiece design information storage unit 130 in the first embodiment of the present invention.

[0031] The workpiece design information table 131 includes an ID column 132, an arrangement position and orientation column 133, and a shape column 134.

[0032] In the ID column 132, numbers for identifying the components constituting the workpiece are stored.

[0033] In the arrangement position and orientation column 133, information representing the arrangement position and orientation of each component is stored.

[0034] In the shape column 134, polygon mesh information representing the shape of each component is stored. For example, the shape column 134 includes a face number column 135, a vertex number column 136, and a vertex coordinate column 137.

[0035] In the face number column 135, numbers for identifying the faces constituting the polygon mesh are stored.

[0036] In the vertex number column 136, numbers for identifying the three vertices constituting each face are stored.

[0037] In the vertex coordinate column 137, information representing the coordinates of each vertex is stored.

[0038] FIG. 3B is an explanatory diagram showing an example of a workpiece drawn based on the workpiece design information in Embodiment 1 of the present invention.

[0039] The figure 138 illustrated in FIG. 3B depicts at least a portion of the workpiece that corresponds to the positioning elements when the workpiece is installed in the equipment. The figure 138 includes, for example, a hole into which the cylindrical positioning pin shown in the figure 128 is inserted and a hole into which the diamond pin is inserted.

[0040] In this embodiment, the ID, arrangement position and orientation, and shape of the parts constituting the workpiece are described as the workpiece design information, but information may be added to and deleted from the workpiece design information as necessary. This embodiment does not limit the information to be described as the workpiece design information.

[0041] FIG. 4A is an explanatory diagram showing an example of the arrangement design information stored in the arrangement design information storage unit 140 in Embodiment 1 of the present invention.

[0042] The arrangement design information table 141 includes an equipment arrangement position and orientation column 142 and a workpiece arrangement position and orientation column 143.

[0043] In the equipment arrangement position and orientation column 142, information representing the arrangement position and orientation of the equipment is stored.

[0044] In the workpiece arrangement position and orientation column 143, information representing the arrangement position and orientation of the workpiece is stored.

[0045] FIG. 4B is an explanatory diagram showing an example of a figure in which the equipment based on the equipment design information and the workpiece based on the workpiece design information in Embodiment 1 of the present invention are arranged and drawn based on the arrangement design information.

[0046] Specifically, the graphic 144 shown in FIG. 4B is obtained by arranging the facility graphic 128 and the work graphic 138 based on the layout design information.

[0047] In this embodiment, the facility arrangement position and orientation and the work arrangement position and orientation are described as the layout design information. However, information may be added to or deleted from the layout design information as necessary. This embodiment does not limit the information described as the layout design information.

[0048] FIG. 5 is a flowchart showing an example of the position deviation calculation procedure executed by the position deviation calculation device 100 in Embodiment 1 of the present invention.

[0049] Hereinafter, with reference to FIGS. 1 and 5, the processing flow in the position deviation calculation device 100 will be described.

[0050] <Positioning element extraction> In the first step shown in FIG. 5, when the position deviation calculation device 100 starts processing, the positioning element extraction unit 170 extracts a positioning element having a function of determining the position of the work with respect to the facility, using the facility design information, the work design information, and the layout design information of the work with respect to the facility as inputs (S171).

[0051] FIG. 6 is a flowchart showing an example of the flow of the process S171 in which the positioning element extraction unit 170 in Embodiment 1 of the present invention extracts a positioning element.

[0052] First, the positioning element extraction unit 170 extracts the contact portion between the facility and the work (S172). Note that the contact portion between the facility and the work is, for example, a collection of surfaces among the surfaces constituting the polygon mesh representing the shape of the facility, where the distance to the work is less than the threshold value.

[0053] Next, the positioning element extraction unit 170 divides the contact parts on the equipment side among the extracted contact parts into basic shapes such as a cylindrical surface, a plane, a straight line, and a point, and extracts each of them as a positioning element (S173). Here, the cylindrical surface is a collection of surfaces among the surfaces constituting the contact part, where all the normal lines of the annularly adjacent surfaces pass through the cylindrical axis straight line. Also, the plane is a collection of surfaces among the surfaces constituting the contact part, where the angle formed by the normal lines of the adjacent surfaces is less than the threshold value.

[0054] Next, the positioning element extraction unit 170 extracts the work-side contact part corresponding to each extracted positioning element as the element to be positioned (S174). Here, the work-side contact part is a collection of surfaces among the surfaces constituting the polygon mesh representing the shape of the work, where the distance from the positioning element is less than the threshold value.

[0055] Through the above processing, it is possible to automatically extract the positioning elements having the function of determining the position of the work with respect to the equipment.

[0056] <Calculation of positioning direction> In the second procedure shown in FIG. 5, the positioning direction calculation unit 180 calculates the positioning direction of the positioning element (S181).

[0057] FIG. 7 is a flowchart showing an example of the flow of the process S181 in which the positioning direction calculation unit 180 in the first embodiment of the present invention calculates the positioning direction.

[0058] First, the positioning direction calculation unit 180 determines whether the shape of the positioning element is a cylindrical surface (S182). When the positioning element is a cylindrical surface, the positioning direction calculation unit 180 analyzes the shape of the cylindrical surface to extract the cylindrical axis, and calculates two directions perpendicular to the cylindrical axis as the positioning direction (S183). Here, the cylindrical axis is a straight line through which the normal lines of all the surfaces constituting the cylindrical surface pass.

[0059] When the shape of the positioning element is not a cylindrical surface, the positioning direction calculation unit 180 determines whether the shape of the positioning element is a plane (S184). Further, when the positioning element is a plane, the positioning direction calculation unit 180 analyzes the shape of the plane to extract the normal direction of the plane, and calculates the normal direction of the plane as the positioning direction (S185). The reason is that the workpiece in contact with the equipment on the plane is fixed in the normal direction of the plane.

[0060] When the positioning element is not a plane, the positioning direction calculation unit 180 calculates the normal direction of the element to be positioned on the workpiece side as the positioning direction (S186). Here, the reason for using the element to be positioned on the workpiece side for calculating the positioning direction is that when the positioning element on the equipment side is a line or a point, its normal direction cannot be determined and the positioning direction cannot be uniquely determined. When the shape of the positioning element on the equipment side is a point or a line, the corresponding element to be positioned on the workpiece side is a surface, and the workpiece is positioned in the normal direction of this surface. Therefore, the positioning direction calculation unit 180 calculates the normal direction of the element to be positioned on the workpiece side as the positioning direction.

[0061] Through the above processing, the positioning direction of the positioning element can be automatically calculated.

[0062] <Equipment position deviation calculation> In the third procedure shown in FIG. 5, the equipment position deviation calculation unit 190 calculates the position deviation of the equipment (S191).

[0063] FIG. 8 is a flowchart showing an example of the flow of the process S191 in which the equipment position deviation calculation unit 190 in the first embodiment of the present invention calculates the position deviation of the equipment.

[0064] First, the equipment misalignment calculation unit 190 calculates the measured misalignment amount as the positioning element misalignment amount based on the result of the positioning element misalignment measurement unit 200 measuring the misalignment amount in the positioning direction of the positioning element on the actual machine (S192). In measuring the misalignment amount, it is necessary to appropriately set the orientation of the sensor according to the type of sensor that constitutes the positioning element misalignment measurement unit 200. For example, when using a camera as the sensor, in order to sense misalignment in the 2D captured image, it is desirable to set the direction perpendicular to the positioning direction as the line-of-sight direction. Also, when using a distance measurement sensor as the sensor, it is desirable to make the positioning direction parallel to the emission direction of ultrasonic waves or lasers.

[0065] Next, the equipment misalignment calculation unit 190 calculates the actual arrangement of the positioning elements by moving the designed arrangement of the positioning elements by the measured misalignment amount (S193).

[0066] Next, the equipment misalignment calculation unit 190 calculates the parallel movement amount and rotational movement amount of the equipment such that all the positioning elements move from the designed arrangement to the actual arrangement, and acquires the calculated movement amount as the equipment misalignment (S194). For this calculation, an alignment method typified by the ICP (Iterative Closest Point) algorithm may be used.

[0067] Finally, the equipment misalignment calculation unit 190 stores the calculated positioning element misalignment and equipment misalignment in the positioning element misalignment information storage unit 150 and the equipment misalignment information storage unit 160.

[0068] FIG. 9 is an explanatory diagram showing an example of the positioning element misalignment information and equipment misalignment information displayed on the display unit 220 in the first embodiment of the present invention.

[0069] First, on an image representing the appearance of the equipment configured based on the equipment design information stored in the equipment design information storage unit 120, the equipment misalignment direction and the equipment misalignment amount stored in the equipment misalignment information storage unit 160 are displayed (equipment misalignment display unit 221). In the example of FIG. 9, the posture is represented by the misalignment amounts in the directions of the respective coordinate axes and the rotation amounts around the respective coordinate axes in the orthogonal coordinate system. However, other coordinate systems such as a cylindrical coordinate system or other posture representations such as quaternions may also be used.

[0070] Also, on an image representing the appearance of the equipment configured based on the equipment design information stored in the equipment design information storage unit 120, one or more positioning elements extracted in the process S171 of extracting the positioning elements are highlighted. In the example of FIG. 9, the first positioning element (positioning element misalignment display unit 222), the second positioning element (positioning element misalignment display unit 223), the third positioning element (positioning element misalignment display unit 224), and the fourth positioning element (positioning element misalignment display unit 225) are highlighted by hatching. Further, for each positioning element, the respective positioning element misalignment direction and the equipment misalignment amount stored in the positioning element misalignment information storage unit 150 are displayed.

[0071] When adjusting the equipment misalignment, the arrangement of the equipment is corrected so that the equipment misalignment amount and the positioning element misalignment amount displayed on the display unit 220 become zero. In particular, when manually adjusting the equipment misalignment, the operation of adjusting the positioning element that is easy to correct is repeated until the equipment misalignment becomes less than a predetermined threshold.

[0072] FIG. 10 is an explanatory diagram showing an example of the positioning element misalignment information stored in the positioning element misalignment information storage unit 150 in the first embodiment of the present invention.

[0073] The positioning element misalignment information table 151 includes a positioning element number column 152, a positioning element misalignment direction column 153, and a positioning element misalignment amount column 154.

[0074] In the positioning element number column 152, a number for identifying the extracted positioning element is stored.

[0075] In the positioning element displacement direction column 153, information indicating the displacement direction of the calculated positioning element is stored.

[0076] In the positioning element displacement amount column 154, information indicating the displacement amount of the calculated positioning element is stored.

[0077] FIG. 10 shows, as an example, a positioning element displacement information table 151 in which the displacement directions and displacement amounts of the positioning elements 1 to 4 shown in FIG. 9 are stored.

[0078] In this description, the positioning element number, the positioning element displacement direction, and the positioning element displacement amount are described as positioning element displacement information, but information may be added to and deleted from the positioning element displacement information as necessary. This embodiment does not limit the information described as the positioning element displacement information.

[0079] FIG. 11 is an explanatory diagram showing an example of the equipment displacement information stored in the equipment displacement information storage unit 160 in Embodiment 1 of the present invention.

[0080] The equipment displacement information table 161 includes an equipment displacement amount column 162.

[0081] In the equipment displacement amount column 162, information indicating the calculated displacement amount of the equipment is stored.

[0082] FIG. 11 shows, as an example, an equipment displacement information table 161 in which the displacement direction and displacement amount of the equipment shown in FIG. 9 are stored.

[0083] In this embodiment, the equipment displacement amount is described as the equipment displacement information, but information may be added to and deleted from the equipment displacement information table 161 as necessary. This embodiment does not limit the information described in the equipment displacement information table 161.

[0084] Here, with reference to FIGS. 9 to 11, specific examples of the positioning element misalignment and the equipment misalignment will be described. In the positioning element misalignment display units 222 to 225 of FIG. 9, examples of the direction and amount of misalignment of the positions of the respective positioning elements measured on the actual machine with respect to the positions of the respective positioning elements specified from the design information when the equipment shown in FIG. 2B and the workpiece shown in FIG. 3B are arranged as shown in FIG. 4B are shown. Further, in the equipment misalignment display unit 221, examples of the direction and amount of misalignment of the equipment specified from the misalignment of the above-described positioning elements are shown.

[0085] In the positioning element misalignment display unit 222, the misalignment direction and the amount of misalignment of the first positioning element are displayed. The first positioning element is the cylindrical side surface (cylindrical surface) of a cylindrical pin. When the positioning element is a cylindrical surface, the positioning direction is any direction in a plane orthogonal to the cylindrical axis (any direction in the XY plane in the example of FIG. 9). As shown in FIG. 10, the misalignment direction of the first positioning element is the direction in the XY plane, which is the positioning direction, where X = 0.71 and Y = -0.72, and the amount of misalignment is +4.2 mm.

[0086] In the positioning element misalignment display unit 223, the misalignment direction and the amount of misalignment of the second positioning element are displayed. The second positioning element is the upper surface of the base of the positioning pin. When the positioning element is a plane, the positioning direction is the direction orthogonal to the plane (the Z-axis direction in the example of FIG. 9). As shown in FIG. 10, the misalignment direction of the second positioning element is the positive direction of the Z-axis, and the amount of misalignment is +0.1 mm.

[0087] In the positioning element misalignment display unit 224, the misalignment direction and the amount of misalignment of the third positioning element are displayed. The third positioning element is one of the plurality of planar side surfaces of the diamond pin. When the positioning element is a plane, the positioning direction is the direction orthogonal to the plane (the Y-axis direction in the example of FIG. 9). As shown in FIG. 10, the misalignment direction of the third positioning element is the negative direction of the Y-axis, and the amount of misalignment is +0.6 mm.

[0088] In the positioning element displacement display unit 225, the displacement direction and displacement amount of the fourth positioning element are displayed. The fourth positioning element is another one of the plurality of planar side surfaces of the diamond pin. When the positioning element is a plane, the positioning direction is the direction orthogonal to the plane (the Y-axis direction in the example of FIG. 9). As shown in FIG. 10, the displacement direction of the fourth positioning element is the negative direction of the Y-axis, and the displacement amount is +0.6 mm.

[0089] In the equipment displacement display unit 221, the displacement direction and displacement amount of the equipment calculated based on the displacement directions and displacement amounts of the first to fourth positioning elements described above are displayed. As shown in FIG. 11, the displacement direction and displacement amount of the equipment are +3.0 mm in the X-axis direction, -3.1 mm in the Y-axis direction, +0.1 mm in the Z-axis direction, +0.1° around the X-axis, +0.2° around the Y-axis, and +1.3° around the Z-axis.

[0090] These are calculated so as to satisfy the displacement directions and displacement amounts of all the positioning elements displayed in the positioning element displacement display units 222 to 225. In other words, when the displacement displayed in the equipment displacement display unit 221 is applied to the equipment, the displacement directions and displacement amounts of the respective positioning elements of the equipment become as displayed in the positioning element displacement display units 222 to 225.

[0091] As described above, according to this embodiment, based on the positioning elements calculated from the design information and the displacements of the positioning elements measured in the actual machine, the displacement of the equipment can be automatically calculated, and the man-hours for adjusting the displacement of the equipment can be reduced.

Embodiment

[0092] Next, Example 2 of the present invention will be described. In Example 2, in the equipment where the robot arranges the workpiece on the equipment, a system for correcting the target position and orientation of the robot based on the calculation result of the misalignment described in Example 1 will be described. Except for the differences described below, each part of the system in Example 2 has the same function as each part with the same reference numeral in Example 1 shown in FIGS. 1 to 11, so their descriptions will be omitted.

[0093] FIG. 12 is a block diagram showing an example of the schematic configuration of the misalignment calculation device in Example 2 of the present invention.

[0094] Descriptions of parts that are not different from FIG. 1 will be omitted. As a difference from FIG. 1, the misalignment calculation device 300 includes, in the storage unit 111, as input information, a robot arrangement information storage unit 310 and a robot target position and orientation storage unit 320, and includes, as output information, a robot target position and orientation correction unit 330. Further, the misalignment calculation device 300 includes a robot target position and orientation correction plan storage unit 340 in the calculation unit 112.

[0095] The robot arrangement information storage unit 310 stores information regarding the arrangement of the robot with respect to the equipment.

[0096] The robot target position and orientation storage unit 320 stores the target position and orientation when the robot performs a predetermined task.

[0097] The robot target position and orientation correction unit 330 corrects the robot target position and orientation stored in the robot target position and orientation storage unit 320 to a robot target position and orientation considering the misalignment of the equipment, based on the information regarding the arrangement of the robot with respect to the equipment stored in the robot arrangement information storage unit 310 and the robot target position and orientation stored in the robot target position and orientation storage unit 320.

[0098] The robot target position and orientation correction plan storage unit 340 stores the correction plan of the robot target position and orientation corrected by the robot target position and orientation correction unit 330.

[0099] FIG. 13 is an explanatory diagram showing an example of the robot placement information stored in the robot placement information storage unit 310 in the second embodiment of the present invention.

[0100] The robot placement information table 311 includes a robot placement position and orientation column 312.

[0101] In the robot placement position and orientation column 312, information representing the placement position and orientation of the robot is stored. For example, in the robot placement position and orientation column 312, coordinate values in a Cartesian coordinate system may be stored as the placement position of the robot, and the amount of rotation around each coordinate axis in the Cartesian coordinate system may be stored as the placement orientation of the robot.

[0102] In this embodiment, the placement position and orientation of the robot are described as the robot placement information, but information may be added to and deleted from the robot placement information as necessary. This embodiment does not limit the information described as the robot placement information.

[0103] FIG. 14 is an explanatory diagram showing an example of the robot target position and orientation information stored in the robot target position and orientation storage unit 320 in the second embodiment of the present invention.

[0104] The robot target position and orientation information table 321 includes a robot target position and orientation column 322.

[0105] In the robot target position and orientation column 322, information representing the target position and orientation of the robot's end effector is stored. For example, in the robot target position and orientation column 322, coordinate values in a Cartesian coordinate system may be stored as the target position of the robot's end effector, and the amount of rotation around each coordinate axis in the Cartesian coordinate system may be stored as the target orientation of the robot's end effector.

[0106] In this embodiment, the target position and orientation of the robot's end effector are described as the robot target position and orientation information, but information may be added to and deleted from the robot target position and orientation information as necessary. This embodiment does not limit the information described as the robot target position and orientation information.

[0107] FIG. 15 is a flowchart showing an example of the processing flow of the misalignment calculation device 300 in the second embodiment of the present invention.

[0108] Hereinafter, with reference to FIGS. 12 and 15, the processing flow in the misalignment calculation device 300 will be described.

[0109] The first step (S171), the second step (S181), and the third step (S191) shown in FIG. 15 are the same as those shown in FIG. 2, and thus the description thereof will be omitted.

[0110] In the fourth step shown in FIG. 15, the robot target position and orientation correction unit 330 corrects the robot target position and orientation stored in the robot target position and orientation storage unit 320 to a robot target position and orientation considering the facility misalignment based on the robot target position and orientation (S331).

[0111] FIG. 16 is a flowchart showing an example of the processing flow of the process S331 in which the robot target position and orientation correction unit 330 corrects the robot target position and orientation in the second embodiment of the present invention.

[0112] First, the robot target position and orientation correction unit 330 uses the information on the robot's arrangement with respect to the facility stored in the robot arrangement information storage unit 310 to convert the facility misalignment stored in the facility misalignment information storage unit 160 into the robot coordinate system, and calculates it as the facility misalignment in the robot coordinate system (S332).

[0113] Next, the robot target position and orientation correction unit 330 moves the robot target position and orientation stored in the robot target position and orientation storage unit 320 by the amount of the calculated facility misalignment in the robot coordinate system, and calculates the moved robot target position and orientation as the robot target position and orientation amendment (S333).

[0114] FIG. 17 is an explanatory diagram showing an example of the robot target position and orientation amendment information stored in the robot target position and orientation amendment storage unit 340 in the second embodiment of the present invention.

[0115] The robot target position and orientation amendment table 341 includes a robot target position and orientation amendment column 342.

[0116] In the robot target position and orientation amendment column 342, information representing the calculated target position and orientation amendment of the robot's hand is stored. For example, in the robot target position and orientation amendment column 342, as the amendment of the target position of the robot's hand, the amount of movement in each coordinate axis direction in the orthogonal coordinate system may be stored, and as the amendment of the target orientation of the robot's hand, the amount of rotation around each coordinate axis in the orthogonal coordinate system may be stored.

[0117] In this embodiment, the target position and orientation amendment of the robot's hand is described as robot target position and orientation amendment information, but information may be added and deleted as necessary for the robot target position and orientation amendment information. This embodiment does not limit the information described as the robot target position and orientation amendment information.

[0118] By the above processing, instead of manually adjusting the misalignment of the equipment, the target position and orientation can be automatically corrected on the robot side according to the misalignment, so that the man-hours for adjusting the misalignment of the equipment can be reduced.

[0119] As described above, according to this embodiment, the positioning elements can be extracted from the design information, the misalignment of the equipment can be automatically calculated, and the man-hours for adjusting the misalignment of the equipment can be reduced.

[0120] Also, the system of the embodiment of the present invention may be configured as follows.

[0121] (1) A misalignment calculation device (e.g., misalignment calculation device 100 or 300) having a calculation unit (e.g., calculation unit 112) and a storage unit (e.g., storage unit 111), wherein the storage unit holds equipment design information indicating the dimensions and shape of the components of the equipment, workpiece design information (e.g., work design information) indicating the dimensions and shape of the workpiece to be processed by the equipment, and arrangement design information indicating the arrangement of the equipment and the workpiece, and the calculation unit extracts the contact portion of the equipment with the workpiece based on the equipment design information, workpiece design information, and arrangement design information (e.g., S171, S172), extracts one or more positioning elements from the contact portion, each of which corresponds to a predetermined shape (e.g., S171, S173), calculates the positioning direction of each positioning element based on the shape of each positioning element (e.g., S181), calculates the misalignment amount of the positioning direction of each positioning element of the actual equipment with respect to the position of each positioning element specified by the equipment design information, workpiece design information, and arrangement design information based on the measurement results of the actual equipment (e.g., S191, S192), and calculates the misalignment direction and misalignment amount of the equipment based on the misalignment amount of the positioning direction of each measured positioning element (e.g., S191, S193 - S195).

[0122] Thereby, the shape of the contact portion can be analyzed from the design information of the equipment and the workpiece and the arrangement design information of the workpiece with respect to the equipment to extract the positioning elements, and the misalignment of the equipment can be automatically calculated, thereby reducing the man-hours for adjusting the misalignment of the equipment.

[0123] (2) In the above (1), the calculation unit extracts, as the contact portion, the portion of the equipment where the distance from the workpiece is smaller than a predetermined threshold based on the equipment design information, workpiece design information, and arrangement design information. The predetermined shapes include a cylindrical surface, a plane, a straight line, and a point. The calculation unit extracts one or more positioning elements from the contact portion, each of which corresponds to a cylindrical surface, a plane, a straight line, and a point.

[0124] Thereby, the positioning elements can be appropriately extracted.

[0125] (3) In the above (2), the calculation unit extracts the contact portion of the work object corresponding to each positioning element as the element to be positioned (for example, S171, 174). When the shape of the positioning element is a cylindrical surface, the direction perpendicular to the cylindrical axis corresponding to the cylindrical surface is calculated as the positioning direction (for example, S183). When the shape of the positioning element is a plane, the normal direction of the plane is calculated as the positioning direction (for example, S185). When the shape of the positioning element is a straight line or a point, the normal direction of the element to be positioned corresponding to the positioning element is calculated as the positioning direction (for example, S186). Thus, an appropriate positioning direction can be determined for each positioning element.

[0126] (4) In the above (1), the calculation unit calculates the displacement direction and displacement amount of the equipment that satisfy all the displacement amounts in the positioning direction of each measured positioning element (for example, S194).

[0127] Thus, the displacement of the equipment can be accurately grasped.

[0128] (5) In the above (1), it further has a display unit (for example, display unit 220) that displays the displacement amount in the positioning direction of each positioning element, and the displacement direction and displacement amount of the equipment.

[0129] This makes it easier for the user to grasp and confirm the displacement.

[0130] (6) In the above (1), the storage unit further holds robot information indicating the arrangement of the robot that installs the work object on the equipment, and robot target position and orientation information indicating the target position and orientation when the robot installs the work object on the equipment. The calculation unit corrects the target position and orientation based on the displacement direction and displacement amount of the equipment (for example, S331). Configuration This enables automatic correction of the target position and orientation on the robot side according to the displacement, instead of manually adjusting the displacement of the equipment, thus reducing the man-hours for adjusting the displacement of the equipment.

[0131] ​

[0132] (7) In the above (1), the misalignment calculation device further includes a measurement unit (for example, the positioning element misalignment measurement unit 200) that measures the actual equipment, and the measurement unit includes at least one of an optical camera that photographs the equipment and the work object, and a distance measurement sensor that measures the distance to the equipment and the work object.

[0133] Thereby, the misalignment direction and misalignment amount of the actual machine can be appropriately measured.

[0134] Note that the present invention is not limited to the above-described embodiments, and various modifications are included. For example, the above-described embodiments have been described in detail for better understanding of the present invention, and are not necessarily limited to those having all the configurations described. Also, a part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment. Also, for a part of the configuration of each embodiment, addition, deletion, or replacement with other configurations is possible.

[0135] In addition, each of the above configurations, functions, processing units, processing means, etc. may be realized in hardware by designing a part or all of them, for example, by an integrated circuit. Also, each of the above configurations, functions, etc. may be realized in software by a processor interpreting and executing a program that realizes each function. Information such as a program, table, file, etc. that realizes each function can be stored in a storage device such as a non-volatile semiconductor memory, a hard disk drive, an SSD (Solid State Drive), or a computer-readable non-temporary data storage medium such as an IC card, an SD card, or a DVD.

[0136] Also, the control lines and information lines show those considered necessary for explanation, and not necessarily all the control lines and information lines are shown on the product. In practice, it may be considered that almost all the components are interconnected.

Explanation of Reference Numerals

[0137] 100 Position deviation calculation device 110 Input section 111 Memory section 112 Calculation section 120 Equipment design information memory section 121 Equipment design information table 122 ID column 123 Arrangement position and orientation column 124 Shape column 125 Face number column 126 Vertex number column 127 Vertex coordinate column 130 Work design information memory section 131 Work design information table 132 ID column 123 Arrangement position and orientation column 124 Shape column 125 Face number column 126 Vertex number column 127 Vertex coordinate column 140 Arrangement design information memory section 141 Arrangement design information table 142 Equipment arrangement position and orientation column 143 Work arrangement position and orientation column 150 Positioning element position deviation information memory section 151 Positioning element position deviation information table 152 Positioning element number column 153 Positioning element position deviation direction column 154 Positioning element position deviation amount column 160 Equipment position deviation information memory section 161 Equipment position deviation information table 162 Equipment position deviation amount column 170 Positioning element extraction section 180 Positioning direction calculation section 190 Equipment position deviation calculation section 200 Positioning element position deviation measurement section 210 Output section 220 Display section 221 Equipment position deviation display section 222, 223, 224, 225 Position Determination Element Position Deviation Display Section 300 Position Deviation Calculation Device 310 Robot Arrangement Information Storage Section 311 Robot Arrangement Information Table 312 Robot Arrangement Position and Orientation Column 320 Robot Target Position and Orientation Storage Section 321 Robot Target Position and Orientation Table 322 Robot Target Position and Orientation Column 330 Robot Target Position and Orientation Correction Section 340 Robot Target Position and Orientation Amendment Storage Section 341 Robot Target Position and Orientation Amendment Table 342 Robot Target Position and Orientation Amendment Column

Claims

1. A misalignment calculation device having an arithmetic unit and a memory unit, wherein the memory unit holds equipment design information indicating the dimensions and shape of the components of the equipment, workpiece design information indicating the dimensions and shape of the workpiece to be processed by the equipment, and arrangement design information indicating the arrangement of the equipment and the workpiece, and the arithmetic unit extracts a contact portion between the equipment and the workpiece based on the equipment design information, the workpiece design information, and the arrangement design information, extracts one or more positioning elements from the contact portion, each of which corresponds to any of a predetermined shape, calculates the positioning direction of each positioning element based on the shape of each positioning element, calculates the amount of misalignment in the positioning direction of each positioning element of the actual equipment with respect to the position of each positioning element specified by the equipment design information, the workpiece design information, and the arrangement design information based on the measurement result of the actual equipment, and calculates the misalignment direction and the amount of misalignment of the equipment based on the amount of misalignment in the positioning direction of each measured positioning element. A misalignment calculation device characterized by the above.

2. The misalignment calculation device according to claim 1, wherein the arithmetic unit extracts, as the contact portion, a portion of the equipment where the distance from the workpiece is smaller than a predetermined threshold based on the equipment design information, the workpiece design information, and the arrangement design information, the predetermined shape includes a cylindrical surface, a plane, a straight line, and a point, and the arithmetic unit extracts one or more positioning elements from the contact portion, each of which corresponds to a cylindrical surface, a plane, a straight line, and a point. A misalignment calculation device characterized by the above.

3. The misalignment calculation device according to claim 2, wherein the arithmetic unit extracts the contact portion of the workpiece corresponding to each positioning element as a to-be-positioned element, when the shape of the positioning element is a cylindrical surface, calculates the direction perpendicular to the cylindrical axis corresponding to the cylindrical surface as the positioning direction, when the shape of the positioning element is a plane, calculates the normal direction of the plane as the positioning direction, and when the shape of the positioning element is a straight line or a point, calculates the normal direction of the to-be-positioned element corresponding to the positioning element as the positioning direction. A misalignment calculation device characterized by the above.

4. The misalignment calculation device according to claim 1, The calculation unit calculates a displacement direction and a displacement amount of the facility that satisfy all the displacement amounts in the displacement direction of each of the measured positioning elements. A displacement calculation device characterized by this.

5. The displacement calculation device according to claim 1, The displacement calculation device further includes a display unit that displays the displacement amount in the displacement direction of each of the positioning elements, and the displacement direction and the displacement amount of the facility.

6. The displacement calculation device according to claim 1, The storage unit further holds robot arrangement information indicating the arrangement of a robot that installs the work object on the facility, and robot target position and attitude information indicating a target position and attitude when the robot installs the work object on the facility. The calculation unit corrects the target position and attitude based on the displacement direction and the displacement amount of the facility. A displacement calculation device characterized by this.

7. The displacement calculation device according to claim 1, The displacement calculation device further includes a measurement unit that measures the actual facility, The measurement unit includes at least one of an optical camera that photographs the facility and the work object, and a distance measurement sensor that measures the distance to the facility and the work object. A displacement calculation device characterized by this.

8. A displacement calculation method executed by a computer system having a calculation unit and a storage unit, The storage unit holds facility design information indicating the dimensions and shape of the components of the facility, work object design information indicating the dimensions and shape of the work object by the facility, and arrangement design information indicating the arrangement of the facility and the work object. The displacement calculation method is as follows: A first step in which the calculation unit extracts a contact portion between the facility and the work object based on the facility design information, the work object design information, and the arrangement design information; A second step in which the calculation unit extracts one or more positioning elements each corresponding to a predetermined shape from the contact portion; A third step in which the calculation unit calculates the positioning direction of each of the positioning elements based on the shape of each of the positioning elements; A fourth step in which the calculation unit calculates a displacement amount in the positioning direction of each of the positioning elements of the actual facility with respect to the position of each of the positioning elements specified by the facility design information, the work object design information, and the arrangement design information based on the measurement result of the actual facility. The displacement calculation method is characterized by including: a fifth step in which the calculation unit calculates the displacement direction and displacement amount of the facility based on the displacement amounts of the respective positioning elements in the positioning direction that have been measured.

9. The displacement calculation method according to claim 8, wherein in the first step, the calculation unit extracts, as the contact portion, a portion of the facility where the distance from the work object is smaller than a predetermined threshold value, based on the facility design information, the work object design information, and the layout design information. The predetermined shape includes a cylindrical surface, a flat surface, a straight line, and a point. The displacement calculation method is characterized in that in the second step, the calculation unit extracts one or more positioning elements corresponding to the cylindrical surface, the flat surface, the straight line, and the point, respectively, from the contact portion.

10. The displacement calculation method according to claim 9, wherein in the second step, the calculation unit extracts, as the element to be positioned, the contact portion of the work object corresponding to each positioning element. In the third step, the calculation unit when the shape of the positioning element is a cylindrical surface, calculates the direction orthogonal to the cylindrical axis corresponding to the cylindrical surface as the positioning direction; when the shape of the positioning element is a flat surface, calculates the normal direction of the flat surface as the positioning direction; when the shape of the positioning element is a straight line or a point, calculates the normal direction of the element to be positioned corresponding to the positioning element as the positioning direction. The displacement calculation method is characterized by this.

11. The displacement calculation method according to claim 8, wherein in the fifth step, the calculation unit calculates the displacement direction and displacement amount of the facility that satisfy all of the displacement amounts of the respective measured positioning elements in the positioning direction. The displacement calculation method is characterized by this.

12. The displacement calculation method according to claim 8, wherein the computer system further includes a display unit, and the displacement calculation method further includes a step in which the display unit displays the displacement amounts of the respective positioning elements in the positioning direction, and the displacement direction and displacement amount of the facility. The displacement calculation method is characterized by this.

13. The displacement calculation method according to claim 8, The memory unit further holds robot placement information indicating the placement of the robot that installs the work object on the facility, and robot target position and orientation information indicating the target position and orientation when the robot installs the work object on the facility. The position deviation calculation method is characterized in that the calculation unit further includes a procedure for correcting the target position and orientation based on the position deviation direction and amount of the facility.

14. The position deviation calculation method according to claim 8, The computer system further includes a measurement unit that measures the actual facility. The measurement unit includes at least one of an optical camera that photographs the facility and the work object, and a distance measurement sensor that measures the distance to the facility and the work object.

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