Control device and control system

Abstract

Provided is a control device that is for controlling an industrial machine and that can detect missed machining in a simple manner. This control device for controlling an industrial machine using a machining tool comprises: a program execution unit for causing the industrial machine to execute a program that includes a start command for starting a machining process and an end command for ending the machining process by the machining tool; and a counting unit for counting, during execution of the program, the number of times of a completion state indicating that machining abnormality has not occurred in the machining process including the start command and the end command and that each of the commands has been executed and completed.

Description

Technical Field

[0001] The present invention relates to a control device and a control system for controlling industrial machines.

Background Art

[0002] In processing such as arc welding and laser processing by industrial machines such as robots and machine tools, a phenomenon often occurs in which the production line temporarily stops due to some abnormality during processing.

[0003] Generally, in such a case, an operator intervenes in the production line as necessary, and after taking appropriate measures, the production line is restarted. Here, in the processing, it is desirable that the position where the production line is temporarily stopped coincides with the position where the production line is restarted after the work. However, due to operator error or the complexity of the processing process, etc., the restart position may be incorrect, and the production line may be restarted with some of the parts to be processed missing.

[0004] In order to check whether all the necessary processing has been performed, a method of inspecting the workpiece after the processing is used. However, if a workpiece containing an unprocessed part is found, it is necessary to execute a process of discarding the workpiece or returning it to the processing line for reprocessing, which increases the man-hours.

[0005] Also, means for checking during processing rather than after processing have been proposed (see, for example, Patent Documents 1 and 2), but it is necessary to check the images one by one, which increases the man-hours.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0007] Therefore, a control device and a control system for controlling an industrial machine capable of detecting missing processing by a simple method are desired.

Means for Solving the Problems

[0008] A control device for controlling an industrial machine using a processing tool according to an aspect of the present disclosure includes a program execution unit that causes the industrial machine to execute a program including a start command for starting a processing operation by the processing tool and an end command for ending the processing operation, and a count unit that counts the number of completion states indicating that the processing operation including the start command and the end command does not cause a processing abnormality and each command is executed and completed during the execution of the program.

[0009] A control system according to an aspect of the present disclosure includes an industrial machine that performs a processing operation using a processing tool, a program execution unit that causes the industrial machine to execute a program including a start command for starting a processing operation by the processing tool and an end command for ending the processing operation, and a count unit that counts the number of completion states indicating that the processing operation including the start command and the end command does not cause a processing abnormality and each command is executed and completed during the execution of the program.

Advantages of the Invention

[0010] According to the present invention, missing processing can be detected by a simple method.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3A

Figure 3B

Figure 4A

Figure 4B

Figure 4C

Figure 5A

Figure 5B

Figure 5C

Figure 6A

Figure 6B

Figure 6C

Figure 7A

Figure 7B

Mode for Carrying Out the Invention

[0012] Hereinafter, an example of an embodiment of the present invention will be described. FIG. 1 is a block diagram showing the configuration of the control system 1 according to this embodiment. The control system 1 is a system for controlling industrial machines such as robots and machine tools. As shown in FIG. 1, the control system 1 includes a robot 10, a control device 20, and a welding torch (processing tool) 30.

[0013] The control system 1 performs arc welding of the object W on the jig 40 by the welding torch 30 attached to the tip of the robot 10 controlled by the control device 20 according to the machining program. In this embodiment, the control system 1 performs welding processing as the machining process, but the control system 1 is also applicable to other machining processes using industrial machines such as laser processing and cutting processing.

[0014] The control device 20 may be a robot control device or a numerical control device for controlling industrial machines such as robots and machine tools. Further, the control device 20 may be a computer device connected to the industrial machine separately from the robot control device or the numerical control device.

[0015] FIG. 2 is a block diagram showing the configuration of the control device 20 according to this embodiment. As shown in FIG. 2, the control device 20 includes a control unit 21, a storage unit 22, a display unit 23, an operation unit 24, and an audio output unit 25.

[0016] The control unit 21 is composed of a processor such as a CPU (Central Processing Unit) and executes various controls in the control device 20. The control unit 21 includes a program execution unit 211, a count unit 212, a machining process determination unit 213, and a notification unit 214.

[0017] The storage unit 22 is composed of a storage device such as a ROM (Read Only Memory), a RAM (Random Access Memory), an HDD (Hard Disk Drive), an SSD (Solid State Drive), etc., and stores various information.

[0018] The display unit 23 is composed of an LCD (Liquid Crystal Display), a CRT (Cathode Ray Tube), etc., and displays various information. The operation unit 24 is composed of a mouse, a keyboard, etc., and accepts various inputs. The audio output unit 25 is composed of a speaker, etc., and outputs audio according to the control of the control unit 21.

[0019] The program execution unit 211 causes the robot 10 to execute a processing program including a start command to start the processing by the welding torch 30 and an end command to end the processing. The counting unit 212 counts the number of times of the completion state indicating that the processing including the start command and the end command is executed and completed without causing a processing abnormality during the execution of the processing program.

[0020] Here, the completion state indicates that the processing including the start command, the end command, and the condition change command is executed and completed without causing a processing abnormality such as interruption, temporary stop, or welding dropout, and each command is executed and completed.

[0021] The processing determination unit 213 compares the number of start commands and the end commands to be executed in the processing program with the number of times of the completion state, and determines whether the processing is completed based on the comparison result. The notification unit 214 outputs the determination result by the processing determination unit 213 through the display unit 23 and / or the voice output unit 25 to notify the user of the determination result.

[0022] Further, the processing program further includes a condition change command for changing the processing conditions in the processing, and the counting unit 212 includes the execution of the condition change command as the completion state.

[0023] Further, during the execution of the processing program, when the processing becomes invalid in a partial section of the processing path, the counting unit 212 holds information regarding the invalidated processing. Then, at the end of the processing, the counting unit 212 does not count the number of times of the completion state corresponding to the invalidated processing. Also, the counting unit 212 counts some or all of the number of times of the completion state at the end of the processing.

[0024] Further, the counting unit 212 can set detailed conditions regarding the completion state. For example, as the detailed conditions, the counting unit 212 may set whether to determine it as the completion state when the welding process cannot be smoothly started and the processing start is retried several times.

[0025] Further, as a detailed condition, the counting unit 212 may set whether to determine the completion state when the welding process is temporarily stopped during the welding process and the welding process is restarted without changing the line of the instruction statement of the processing program.

[0026] Similarly, as a detailed condition, the counting unit 212 may set whether to determine the completion state when the feedback value (for example, current value, voltage value, etc.) regarding the processing state deviates from the threshold value during the welding process. This detailed condition is applied when the feedback value instantaneously deviates from the threshold value but is not in a situation where an alarm is notified and the robot 10 is stopped to stop the production line.

[0027] Further, as a detailed condition, the counting unit 212 may set whether to determine the completion state when the end-of-processing during the welding process is interrupted midway or the end-of-processing fails. When the welding process is arc welding, the robot 10 executes a crater treatment as the end-of-processing.

[0028] FIG. 3A is a diagram showing an example of a processing program according to the present embodiment. FIG. 3B is a diagram showing the welding process according to the present embodiment. The processing program shown in FIG. 3A is a program for causing the robot 10 to execute a welding process by the welding torch 30.

[0029] As shown in FIG. 3B, the robot 10 performs a welding process on the work W according to the processing program. The welding process shown in FIG. 3B moves the welding torch 30 in the welding direction D1 and forms welding beads 51, 52, and 53 on the work W.

[0030] Specifically, in the processing program shown in FIG. 3B, the start instruction "KAKOUKAISHI [1]" corresponds to the start of the processing of the welding bead 51, the start instruction "KAKOUKAISHI [3]" corresponds to the start of the processing of the welding bead 52, and the start instruction "KAKOUKAISHI [4]" corresponds to the start of the processing of the welding bead 53.

[0031] Furthermore, the three end commands "KAKO SYURYO" in the machining program respectively correspond to the completion of machining of the welding beads 51, 52, and 53. Furthermore, the machining condition change command "KAKO JOKEN [2]" in the machining program corresponds to the change of the machining conditions of the welding bead 51.

[0032] As shown in FIG. 3A, the program execution unit 211 causes the robot 10 to execute the machining program. The machining program executes the command "COUNTER [1]=0" to initialize the count of the number of completed states, and the counting unit 212 starts counting the number of completed states.

[0033] Next, the machining program executes the commands from the start command "KAKO KAISHI [1]" (start of machining of the welding bead 51) to the end command "KAKO SYURYO" (end of machining of the welding bead 53).

[0034] Furthermore, the counting unit 212 counts the number of completed states in the machining process from the start command "KAKO KAISHI [1]" (start of machining of the welding bead 51) to the end command "KAKO SYURYO" (end of machining of the welding bead 53).

[0035] For example, as shown in FIG. 3B, when all commands have been executed and completed, the counting unit 212 counts the number of commands from the start command "KAKO KAISHI [1]" to the end command "KAKO SYURYO", that is, "7", as the number of completed states. Here, the counting unit 212 collectively counts the number of completed states of the start command "KAKO KAISHI [1]", the start command "KAKO KAISHI [3]", and the start command "KAKO KAISHI [4]" at the end of each machining.

[0036] Next, the machining program executes the command "IF COUNTER [1]<>7, THEN(ALARM NOTIFICATION)", and the machining process determination unit 213 compares the number of start commands and end commands to be executed in the machining program (that is, "7") with the number of completed states, and determines whether the machining process has been completed based on the comparison result.

[0037] When the number of start commands and end commands to be executed (i.e., "7") matches the number of completion states, the processing determination unit 213 determines that the processing has been completed normally. Then, as a determination result, the notification unit 214 outputs that the processing has been completed by the display unit 23 and / or the voice output unit 25, and notifies the user of the determination result.

[0038] On the other hand, when the number of start commands and end commands to be executed (i.e., "7") does not match the number of completion states, the processing determination unit 213 determines that the processing has not been completed. Then, as a determination result, the notification unit 214 outputs an alarm notification indicating that the processing has not been completed by the display unit 23 and / or the voice output unit 25, and notifies the user of the determination result. As a result, the user can recognize whether there is any omission in the processing.

[0039] FIG. 4A is a diagram showing an example of a processing program according to the present embodiment. FIG. 4B is a diagram showing the number of completion states when the processing according to the present embodiment is completed normally. FIG. 4C is a diagram showing the number of completion states when the processing according to the present embodiment is not completed normally.

[0040] The processing program shown in FIG. 4A is a program from the start command "KAKOUKAISHI [1]" (start of processing of the welding bead 51) to the end command "KAKOUSHURYOH" (end of processing of the welding bead 53) of the processing program shown in FIG. 3.

[0041] When the processing program shown in FIG. 4A is executed, the counting unit 212 counts the number of completion states in the processing from the start command "KAKOUKAISHI [1]" to the end command "KAKOUSHURYOH". Then, in the example shown in FIG. 4B, when all commands are executed and completed, the counting unit 212 counts the number of completion states "7" from the start command "KAKOUKAISHI [1]" to the end command "KAKOUSHURYOH".

[0042] On the other hand, in the example shown in FIG. 4C, it is shown that by an operation of the operation unit 24 by the user or the like, the processing of the welding bead 51 was temporarily stopped, the line of the processing program corresponding to the processing of the welding bead 51 was skipped, and the processing of the next welding bead 52 was started. In this case, the start command "PROCESS START [1]" was executed, but the processing condition change command "PROCESS CONDITION [2]" and the end command "PROCESS COMPLETION" were not executed and completed.

[0043] In this case, since the processing including the above three commands has not been executed and completed by the count unit 212, the count unit 212 does not count the number of completion states. Further, the count unit 212 counts the number "4" of completion states in the processing from the start command "PROCESS START [3]" to the end command "PROCESS COMPLETION" (completion of the processing of the welding bead 53).

[0044] FIGS. 5A to 5C show examples of counting the number of completion states in the processing. FIG. 5A is a diagram showing the completion state when the processing according to the present embodiment is normally completed. As described above, in this case, the count unit 212 counts the number "7" of completion states from the start command "PROCESS START [1]" to the end command "PROCESS COMPLETION".

[0045] FIG. 5B is a diagram showing the completion state when welding is performed from the middle of the processing path in the processing according to the present embodiment. In the example shown in FIG. 5B, since the start command "PROCESS START [3]" was not executed in the welding enabled state and was switched to the welding enabled state in the middle, it is shown that after the welding bead 52 was formed from the middle, the end command "PROCESS COMPLETION" (completion of the processing of the welding bead 52) was completed. In this case, since the processing including the above two commands has not been correctly completed, the count unit 212 does not count each command as the number of completion states.

[0046] FIG. 5C is a diagram showing a completion state when the processing is temporarily stopped during the processing and the welding within the same processing is skipped in the processing according to the present embodiment. In the example shown in FIG. 5C, the start command "KAKOU KAISHI [1]" is executed, but the processing is temporarily stopped within the same welding section, and the lines corresponding to the processing of the welding bead 51 of the processing program are skipped, indicating that the processing condition change command "KAKOU JOUKEN [2]" and the end command "KAKOU SHURYOURYOU" are executed. In this case, since the welding within the same processing corresponding to the start command "KAKOU KAISHI [1]" has not been completed, the counting unit 212 does not count it as the number of completion states.

[0047] As shown in FIGS. 5B and 5C, the counting unit 212 holds information regarding the processing that has become invalid when the processing becomes invalid in a partial section of the processing path during the execution of the processing program. Then, at the end of the processing, the counting unit 212 does not count the number of completion states corresponding to the processing that has been invalidated.

[0048] FIG. 6A is a diagram showing an example of a processing program according to the present embodiment. FIG. 6B is a diagram showing a completion state when the welding processing according to the present embodiment is normally completed. FIG. 6C is a diagram showing a completion state when the welding processing according to the present embodiment is temporarily stopped during the processing.

[0049] The processing program shown in FIG. 6A is a program for causing the robot 10 to execute a welding process by the welding torch 30. As shown in FIG. 6B, the robot 10 performs a welding process on the workpiece W according to the processing program. The welding process shown in FIG. 6B moves the welding torch 30 in the welding directions D2 and D3 to form an L-shaped welding bead 54 on the workpiece W.

[0050] In the example shown in FIG. 6B, the welding process paused during the execution of the instruction "Chokusen Ichi [2]", indicating that the line of the instruction in the processing program was changed and resumed from the instruction "Chokusen Ichi [7]". When the line is changed in this way, the robot 10 does not perform the welding process from the instruction "Chokusen Ichi [7]" to the instruction "Chokusen Ichi [9]".

[0051] In this case, the count unit 212 holds information regarding the disabled welding process. Then, at the end of the welding process, the count unit 212 does not count the number of completion states corresponding to the disabled processing. That is, in the example shown in FIG. 6B, the count unit 212 counts "0" as the number of completion states.

[0052] FIG. 7A is a diagram showing an example of a processing program according to the present embodiment. FIG. 7B is a diagram showing the completion state when the processing according to the present embodiment pauses during the processing and is changed to the single-step mode.

[0053] The processing program shown in FIG. 7A is a program for causing the robot 10 to perform a welding process by the welding torch 30. As shown in FIG. 7B, the robot 10 performs a welding process on the workpiece W according to the processing program. The welding process shown in FIG. 7B moves the welding torch 30 in the welding direction D4 and forms a linear weld bead 55 on the workpiece W.

[0054] In the example shown in FIG. 7B, the welding process paused during the execution of the instruction "Chokusen Ichi [5]", indicating that the robot 10 changed the operation mode to the single-step mode. Here, the single-step mode is a mode that executes only one line of an instruction.

[0055] When changed to the single-step mode, the robot 10 operates to the position where it executes the instruction "CHOICE ONE [6]", and then does not execute subsequent instructions, and the welding process becomes invalid. Also in this case, similar to the example described above, the counting unit 212 holds information regarding the invalidated welding process. And the counting unit 212 does not count the number of completion states corresponding to the invalidated process at the end of the welding process. That is, in the example shown in FIG. 7B, the counting unit 212 counts "0" as the number of completion states.

[0056] As described above, according to the present embodiment, the control device 20 includes a program execution unit 211 that causes the robot 10 to execute a processing program including a start instruction for starting a processing by the welding torch 30 and an end instruction for ending the processing, and during the execution of the processing program, a counting unit 212 that counts the number of completion states indicating that the processing including the start instruction and the end instruction does not cause a processing abnormality and each instruction is executed and completed.

[0057] Thereby, the control device 20 can detect a missed process when there is a processing instruction that is not executed or when there is a processing instruction that is executed but the processing is not appropriately completed. Since the control device 20 counts the number of processing instructions instead of the number of processing times, it can detect a missed process even when some processes are missing with the same number of processing times. Further, since the control device 20 checks the number of processing instructions, it can detect a missed process by a simple method.

[0058] Also, the processing determination unit 213 compares the number of start instructions and the end instructions to be executed in the processing program with the number of completion states, and determines whether the processing is completed based on the comparison result. The notification unit 214 outputs the determination result by the processing determination unit 213 through the display unit 23 and / or the voice output unit 25 to notify the user of the determination result. Thereby, the control device 20 can notify the user whether the processing is completed.

[0059] Further, the machining program further includes a condition change command for changing machining conditions in the machining process, and the counting unit 212 includes the execution of the condition change command as a completion state. Thereby, the control device 20 can more accurately determine whether the machining process is completed or not by adding the execution of the condition change command to the completion state as well.

[0060] Also, during the execution of the machining program, when the machining process becomes invalid in a partial section of the machining path, the counting unit 212 holds information regarding the invalidated machining process. Then, at the end of the machining process, the counting unit 212 does not count the number of completion states corresponding to the invalidated machining process. Further, the counting unit 212 counts some or all of the number of completion states at the end of the machining process. Thereby, the control device 20 can detect a machining omission even when the command is properly executed but a machining omission occurs midway.

[0061] Also, the counting unit 212 can set detailed conditions regarding the completion state. Specifically, as the detailed conditions, the counting unit 212 may set whether to determine it as a completion state when the welding process cannot be started smoothly and the start of machining is retried several times. Also, as the detailed conditions, the counting unit 212 may set whether to determine it as a completion state when the welding process pauses during the process and the welding process is resumed without changing the lines of the command statements of the machining program.

[0062] Similarly, as the detailed conditions, the counting unit 212 may set whether to determine it as a completion state when a feedback value regarding the machining state (for example, a current value, a voltage value, etc.) deviates from a threshold value during the welding process. Also, as the detailed conditions, the counting unit 212 may set whether to determine it as a completion state when the machining end process is interrupted midway or the machining end process fails during the welding process. With such a configuration, the control device 20 can manage the machining process that matches the user's purpose.

[0063] As described above, embodiments of the present invention have been explained. However, the above control system 1 and control device 20 can be realized by hardware, software, or a combination thereof. Further, the control method performed by the above control system 1 and control device 20 can also be realized by hardware, software, or a combination thereof. Here, being realized by software means being realized by a computer reading and executing a program.

[0064] The program can be stored using various types of non-transitory computer readable media and supplied to a computer. Non-transitory computer readable media include various types of tangible storage media. Examples of non-transitory computer readable media include magnetic recording media (e.g., hard disk drive), magneto-optical recording media (e.g., magneto-optical disk), CD-ROM (Read Only Memory), CD-R, CD-R / W, semiconductor memory (e.g., mask ROM, PROM (Programmable ROM), EPROM (Erasable PROM), flash ROM, RAM (random access memory)).

[0065] Also, each of the above-described embodiments is a preferred embodiment of the present invention. However, the scope of the present invention is not limited to only the above embodiments, and it can be implemented in various modified forms without departing from the gist of the present invention.

Explanation of Reference Numerals

[0066] 1 Control system 10 Robot (Industrial Machine) 20 Control device 21 Control unit 22 Storage unit 23 Display unit 24 Operation unit 25 Voice output unit 211 Program execution unit 212 Counting Unit 213 Processing Judgment Unit 214 Notification Unit 30 Welding Torch (Processing Tool) 40 Jig W Workpiece

Claims

1. A control device for controlling a robot using a welding torch, comprising: a program execution unit that causes the robot to execute a program including a start command for starting a processing operation by the welding torch and an end command for ending the processing operation; a counting unit that counts the number of completion states indicating that the processing operation including the start command and the end command is executed and completed without causing a processing abnormality during the execution of the program; and comprising: the counting unit: during the execution of the program, when the processing operation becomes invalid in a partial section of the processing path, holds information regarding the invalidated processing operation; at the end of the processing operation, does not count the number of completion states corresponding to the invalidated processing operation; a control device.

2. a processing operation determination unit that compares the number of the start command and the end command to be executed in the program with the number of completion states, and determines whether the processing operation is completed based on the comparison result; a notification unit that notifies the determination result by the processing operation determination unit; The control device according to claim 1, comprising:

3. the program further includes a condition change command for changing a processing condition in the processing operation; the counting unit includes execution of the condition change command as the completion state, the control device according to claim 1 or 2.

4. the counting unit counts some or all of the number of completion states at the end of the processing operation, the control device according to any one of claims 1 to 3.

5. the counting unit can set detailed conditions regarding the completion state, the control device according to any one of claims 1 to 3.

6. The control device according to claim 5, wherein the counting unit can set, as the detailed condition, whether to determine the completion state when the processing is retried.

7. The control device according to claim 5, wherein the counting unit can set, as the detailed condition, whether to determine the completion state when the processing is temporarily stopped during the processing and restarted without changing the line of the instruction statement of the program.

8. The control device according to claim 5, wherein the counting unit can set, as the detailed condition, whether to determine the completion state when a feedback value regarding the processing state deviates from a threshold value during the processing.

9. The control device according to claim 5, wherein the counting unit can set, as the detailed condition, whether to determine the completion state when the end processing of the processing is interrupted during the processing or when the end processing of the processing fails.

10. A robot that performs a welding process using a welding torch, A program execution unit that causes the robot to execute a program including a start command for starting the welding process by the welding torch and an end command for ending the welding process, During the execution of the program, a counting unit that counts the number of completion states indicating that the welding process including the start command and the end command does not cause a processing abnormality and each command is executed and completed, comprising The counting unit During the execution of the program, when the welding process becomes invalid in a partial section of the processing path, information regarding the invalidated welding process is held, At the end of the welding process, the number of completion states corresponding to the invalidated welding process is not counted. Control system.

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