Manufacturing system, control method and control program

Abstract

A manufacturing system according to one embodiment of the present invention comprises: at least one measuring sensor (22) which, for a plurality of components constituting an assembly, measures a shape of each component; a shape data storage unit (2522) for storing the shape data acquired by the measuring sensor (22), for each component; an assembly target component group selecting unit (2514) for selecting a first assembly target component group comprising at least two components, to serve as the components of the assembly, from the plurality of components; an assembled state estimating unit (2515) for estimating an assembled state of the assembly on the basis of the shape data of the components belonging to the first assembly target component group; and an assembly execution command unit (2519) for imparting, to an assembly robot (3000), an assembly execution command instructing assembly of the assembly employing the components included in the first assembly target component group, on the basis of a result of the estimation by the assembled state estimating unit (2515).

Description

[Technical Field]

[0001] The present invention relates to a technique for performing an assembly operation such as welding on a plurality of parts. [Background technology]

[0002] Conventionally, techniques have been proposed for generating welding operations for a welding robot based on measurement results of components to be welded. Patent Document 1, in particular, discloses a technique for generating a three-dimensional model from three-dimensional point cloud data of components to be welded obtained by a three-dimensional measurement sensor, and generating welding operations based on the three-dimensional model. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6985464 specification Summary of the Invention

[0004] Even if the dimensional errors of each part are within the tolerance range, when assembling multiple parts by welding or bolting them together to manufacture an assembly, there is a problem that the tolerances of the parts to be assembled do not match well, and a certain percentage of assemblies occur with shape errors that do not fall within the allowable range.

[0005] One aspect of the present invention is a manufacturing system comprising: at least one measurement sensor that measures the shape of each of a plurality of parts that constitute an assembly; a shape data storage unit that stores, for each of the parts, the shape data of the parts acquired by the measurement sensor; a group of parts to be assembled that selects a first group of parts to be assembled that includes at least two parts from the plurality of parts that will become parts of the assembly; an assembly state estimation unit that estimates an assembly state of the assembly, based on the shape data of the parts that belong to the first group of parts to be assembled; and an assembly execution command unit that issues an assembly execution command to an assembly robot, instructing it to assemble the assembly of the assembly using the parts included in the first group of parts to be assembled, based on the result of the estimation by the assembly state estimation unit.

[0006] One aspect of the present invention is a control method for a manufacturing system that uses an assembly robot to manufacture an assembly product in which a plurality of parts are assembled, the control method for a manufacturing system comprising the steps of: acquiring shape data for the plurality of parts that make up the assembly product from measurement results of the shapes of the parts; storing the shape data for each part in a shape data storage unit; selecting a first group of parts to be assembled that is made up of at least two parts that will become parts of the assembly product from the plurality of parts; estimating an assembly state of the assembly product based on the shape data of the parts that belong to the first group of parts to be assembled; and issuing an assembly execution command to an assembly robot that instructs the assembly robot to assemble the assembly product using the parts included in the first group of parts to be assembled based on the result of the estimation.

[0007] One aspect of the present invention is a control program that causes a computer to execute the following: a shape data acquisition process that acquires shape data of multiple parts that make up an assembly from measurement results of the shapes of the parts; a shape data storage process that stores the shape data for each part in a shape data storage unit; a group of parts to be assembled that selects a first group of parts to be assembled that includes at least two parts from the multiple parts that will become parts of the assembly; an assembly state estimation process that estimates an assembly state of the assembly based on the shape data of the parts that belong to the first group of parts to be assembled; and an assembly execution command that issues an assembly execution command to an assembly robot that instructs the robot to assemble the assembly using the parts included in the first group of parts to be assembled based on the result of the estimation.

[0008] Other problems and solutions disclosed in this application will be made clear in the section on preferred embodiments of the invention and the drawings.

[0009] According to the present invention, it is possible to provide a manufacturing system or manufacturing method that can more efficiently select parts that will result in a shape error within an allowable range for the device after the parts are installed. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a diagram illustrating an example of the overall configuration of a manufacturing system 1000 according to an embodiment of the present invention. [Figure 2] FIG. 2 is a diagram illustrating an example of a hardware configuration of a measuring robot according to the present embodiment. [Figure 3] FIG. 2 is a diagram illustrating an example of a hardware configuration of an assembly robot according to the present embodiment. [Figure 4] FIG. 10 is a diagram illustrating an example of a hardware configuration in the case where the measurement robot and the assembly robot according to the present embodiment are realized by a common general-purpose robot. [Figure 5] FIG. 2 is a diagram illustrating an example of the hardware configuration of a cooperative control unit and the like according to the present embodiment. [Figure 6] FIG. 2 is a diagram illustrating an example of the functional configuration of a measurement control unit 2400 according to the present embodiment. [Figure 7]FIG. 2 is a diagram illustrating an example of the functional configuration of a cooperative control unit 2500 according to the present embodiment. [Figure 8] FIG. 2 is a diagram illustrating an example of the functional configuration of an assembly control unit 2600 according to the present embodiment. [Figure 9] FIG. 1 is a diagram illustrating an example of a manufacturing process using a manufacturing system according to an embodiment of the present invention. [Figure 10] FIG. 2 is a diagram showing an example of an overall operation flow of the manufacturing system according to the present embodiment. [Figure 11] FIG. 10 is a diagram showing another example of the overall operation flow of the manufacturing system according to the present embodiment. [Figure 12] FIG. 2 is a diagram illustrating an example of a device manufactured by the manufacturing system of the present embodiment. [Figure 13] 10A and 10B are diagrams illustrating assembly errors that occur in devices manufactured by the manufacturing system of this embodiment. [Figure 14] 10A and 10B are diagrams illustrating assembly errors that occur in devices manufactured by the manufacturing system of this embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] <Details of the First Embodiment> Specific examples of a manufacturing system 1000 according to one embodiment of the present invention will be described below with reference to the drawings. The present invention is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims. In the following description, identical or similar elements in the accompanying drawings will be given identical or similar reference symbols and names, and redundant descriptions of identical or similar elements may be omitted in the description of each embodiment. Furthermore, features shown in each embodiment may also be applied to other embodiments as long as they are not mutually inconsistent.

[0012] 1 is a diagram showing an example of a manufacturing system 1000 according to this embodiment. As shown in FIG. 1, the manufacturing system 1000 according to this embodiment includes an assembly robot 3000 that performs an assembly operation on a first group of components to be assembled in accordance with an assembly execution command output by an assembly execution command unit 2519.

[0013] 1, the manufacturing system 1000 of this embodiment includes an input / output unit 1, a controller 2, one or more measuring robots 2000, one or more measurement control units 2400, a cooperative control unit 2500, one or more assembly control units 2600, and one or more assembly robots 3000. The measuring robot 2000 acquires information about the shape of a first part 41 to be measured using a measurement sensor 22. The measurement control unit 2400 is connected to the measuring robot 2000 via wired or wireless communication so as to be able to communicate with each other. The measurement control unit 2400 controls the measurement operation performed by the measurement sensor 22 mounted on the measuring robot 2000 and the operation of the arm 21 of the measuring robot, and acquires the measurement results. When there are multiple measuring robots 2000, multiple measurement control units 2400 may be provided for each measuring robot. The cooperative control unit 2500 is a control unit that is connected to each measurement control unit 2400 via wire or wirelessly so that they can communicate with each other, and that estimates the shape of a primary assembly that is formed by assembling a first part 41, which is the measurement target, and a second part that is to be assembled with the first part, based on information on the measurement results acquired from each measurement control unit 2400. Here, the cooperative control unit 2500 does not necessarily need to be an independent device from the measurement control unit 2400, and the cooperative control unit 2500 and the measurement control unit 2400 may be implemented in a single device.

[0014] The input / output unit 1 is connected to the cooperative control unit 2500 by wire or wirelessly so as to be able to communicate with each other, and includes an output device (e.g., a display) that displays data stored in each memory unit of the cooperative control unit 2500, as well as an information input device (e.g., a keyboard, a mouse, or a touch panel) that inputs and updates data stored in each memory unit. The controller 2 is connected to the cooperative control unit 2500 by wire or wirelessly so as to be able to communicate with each other, and includes an input unit that inputs instructions to start and stop the operation of the measurement sensor 22 and the arm 21 of the measurement robot 2000.

[0015] The assembly control unit 2600 is connected to the cooperative control unit 2500 via wire or wirelessly so that they can communicate with each other, and receives an assembly execution command from the cooperative control unit 2500. The assembly control unit 2600 is also connected to the assembly robot 3000 via wire or wirelessly so that they can communicate with each other, and when the assembly control unit 2600 receives an assembly execution command from the cooperative control unit 2500, it controls the operations of the welding torch 32 and arm 31 mounted on the assembly robot 3000 based on the assembly execution command, thereby performing the assembly work.

[0016] Fig. 2 is a diagram showing an example of the hardware configuration of the measuring robot 2000. As shown in Fig. 2, the measuring robot 2000 has an arm 21, and the arm 21 is equipped with a measurement sensor 22. The measuring robot 2000 controls the position and orientation of the measurement sensor 22 based on command signals for the position and orientation of the measurement sensor 22 generated by the measurement control unit in accordance with three-dimensional CAD data of the first part 41 to be measured, which is pre-recorded in a three-dimensional CAD data storage unit 2521 of the cooperative control unit 2500, to acquire three-dimensional point cloud data of the first part 41.

[0017] 3 is a diagram showing an example of the hardware configuration of an assembly robot 3000. As shown in FIG. 3, the assembly robot 3000 has an arm 31, on which a welding torch 32 is mounted. Here, what is mounted on the arm 31 does not necessarily have to be a welding torch; instead of the welding torch, a wrench for tightening bolts can be mounted when assembling parts by tightening bolts, and instead of the welding torch, a screwdriver for tightening screws can be mounted when assembling parts by screws. When an assembly execution command is output from the cooperative control unit 2500, the assembly robot 3000 performs an assembly task on multiple parts selected by the assembly target parts group selection unit 2514.

[0018] Fig. 4 is a diagram showing an example of a hardware configuration in which a measurement robot and an assembly robot are realized by a common general-purpose robot. While Fig. 2 and Fig. 3 show examples of a measurement robot specialized for measurement work and an assembly robot specialized for assembly work, respectively, the present invention is not limited to this, and it is also possible to use a general-purpose robot in which both a measurement sensor 22 and a welding torch 23 are mounted on an arm 21, as shown in Fig. 4, to perform the operations performed by the measurement robot and the assembly robot.

[0019] <Hardware> 5 is a diagram showing the hardware configuration of the measurement control unit 2400, the cooperative control unit 2500, and the assembly control unit 2600. The measurement control unit 2400, the cooperative control unit 2500, and the assembly control unit 2600 may be implemented as a general-purpose computer such as a personal computer, or may be logically realized by cloud computing. Note that the illustrated configuration is an example, and other configurations may also be used. For example, some functions provided in the processor 10 may be executed by a server or other terminal external to the measurement control unit 2400, the cooperative control unit 2500, and the assembly control unit 2600.

[0020] The measurement control unit 2400, the cooperation control unit 2500, and the assembly control unit 2600 each include at least a processor 10, a memory 11, a storage 12, a transmitter / receiver 13, etc., which are electrically connected to one another via a bus 15.

[0021] The processor 10 is a computing device that controls the operation of the control units (measurement control unit 2400, cooperation control unit 2500, and assembly control unit 2600) in which it is installed, controls the transmission and reception of data and the like with devices connected by wire or wirelessly at least via the transmission and reception unit 13, and performs information processing necessary for application execution and authentication processing. For example, the processor 10 is a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit), or a CPU and a GPU, and executes programs and the like for this system stored in the storage 12 and deployed in the memory 11 to perform various information processing.

[0022] The memory 11 includes a main memory configured with a volatile storage device such as a DRAM (Dynamic Random Access Memory) and an auxiliary memory configured with a nonvolatile storage device such as a flash memory or an HDD (Hard Disc Drive). The memory 11 is used as a work area for the processor 10, and also stores a BIOS (Basic Input / Output System) that is executed when the control units (measurement control unit 2400, cooperative control unit 2500, and assembly control unit 2600) in which the memory 11 is installed are started, various setting information, and the like.

[0023] The storage 12 stores various programs such as application programs. A database that stores data used for each process may be constructed in the storage 12.

[0024] The transceiver 13 connects to other devices communicably connected to the control unit in which it is installed, and transmits and receives data, etc. in accordance with instructions from the processor. The transceiver 13 may be configured as a wired or wireless communication interface, and if wireless, may be configured as a short-range communication interface such as WiFi, Bluetooth (registered trademark), or BLE (Bluetooth Low Energy).

[0025] A bus 15 is commonly connected to the above elements and transmits, for example, address signals, data signals and various control signals.

[0026] <Measurement operation> 1, 2, and 4, the measurement operation by the measuring robot 2000 or general-purpose robot according to this embodiment will be described. As described above, the measuring robot 2000 has an arm 21 and a measurement sensor 22. Note that the illustrated configuration is an example and is not limited to this configuration. The operation of the arm 21 is controlled by a measurement control unit 2400 based on a three-dimensional robot coordinate system.

[0027] The measurement sensor 22 measures the first part 41 based on a three-dimensional sensor coordinate system. The measurement sensor 22 is, for example, a laser sensor that operates as a three-dimensional scanner, and acquires three-dimensional point cloud data of the first part 41 through measurement. In the three-dimensional point cloud data, for example, each point data has coordinate information in a sensor coordinate system, and the shape of the first part 41 can be grasped from the point cloud. Note that the measurement sensor 22 is not limited to a laser sensor, and may be, for example, an image sensor using a stereo system, or may be a sensor independent of the measurement robot 2000, as long as it can acquire coordinate information in a three-dimensional sensor coordinate system.

[0028] Note that a predetermined calibration may be performed before the work, the robot coordinate system and the sensor coordinate system may be associated with each other, and the user may specify positions (coordinates) based on the sensor coordinate system, so that the operation of the arm 21 and the measurement sensor 22 may be controlled based on the corresponding positions. Furthermore, if the shape of the first part 41 is complex, for example, three-dimensional point cloud data of the first part 41 may be acquired by using multiple measuring robots 2000 or by performing measurement operations multiple times while changing the posture of the measuring robots 2000. The cooperative control unit 2500 then executes processes such as determining the suitability of the first part 41 and determining whether or not it is permitted to be assembled based on the three-dimensional point cloud data. Here, by defining the robot coordinate systems of the multiple measuring robots as the same coordinate system, the three-dimensional point cloud data acquired by each measuring robot may be integrated in a short time, and integrated three-dimensional point cloud data of the entire part to be assembled may be obtained with high accuracy and in a short time. Furthermore, the three-dimensional point cloud data acquired by multiple measurement robots 2000 or multiple measurement operations is integrated by the cooperative control unit 2500, and in order to perform this integration process, the measurement ranges of the three-dimensional point cloud data acquired by multiple measurement robots 2000 or multiple measurement operations are set so that the measurement positions overlap with each other.

[0029] <Assembly operation> 1, 3, and 4, the assembly operation by the assembly robot 3000 or general-purpose robot according to this embodiment will be described. As described above, the assembly robot 3000 or general-purpose robot has an arm 31 and a welding torch 32. Note that the illustrated configuration is an example and is not limiting.

[0030] Welding torch 32 performs the assembly work of first component 41 based on a three-dimensional torch coordinate system. Welding torch 32 is a tool used in fusion welding methods such as arc welding, laser welding, electron beam welding, and plasma arc welding, and outputs an arc, laser, beam, or the like that melts the target components from the welding torch to assemble a group of components to be assembled, including the first component. Note that the welding torch may also be a discharge part for a filler material (adhesive) used in brazing or other brazing processes, or a discharge part for a sealant or adhesive. When components are assembled by bolting, a wrench for tightening bolts can be used instead of the welding torch, or when components are assembled by screws, a screwdriver for tightening screws can be used instead of the welding torch.

[0031] It is also possible to configure the system so that predetermined calibration is performed before the work, the assembly robot 3000 and the torch coordinate system are associated with each other, and the user specifies positions (coordinates) based on the torch coordinate system, so that the arm 31 and the welding torch 32 are controlled to operate based on the corresponding positions. Also, when assembly work is performed using multiple assembly robots, the robot coordinate systems of the multiple assembly robots can be defined in the same coordinate system, thereby enabling the allocation of assembly work to be completed in a short time.

[0032] <Functions of the measurement control unit 2400> 6 is a diagram showing an example of the functional configuration of the measurement control unit 2400. The measurement control unit 2400 includes a measurement condition acquisition unit 2411, an arm control unit 2412, a measurement sensor control unit 2413, a measurement data acquisition unit 2414, and a calibration unit 2415. The measurement condition acquisition unit 2411 receives measurement condition information (information including the position and measurement direction of the measurement sensor 22) related to the measurement operation from the cooperative control unit 2500. The arm control unit 2412 generates an operation command for the arm 21 that satisfies the measurement conditions, and transmits the operation command to the measurement robot 2000 that is communicatively connected, thereby controlling the arm of the measurement robot 2000. Furthermore, the measurement sensor control unit 2413 generates an operation command for the measurement sensor 22 that satisfies the measurement conditions, and transmits the operation command to the measurement sensor 22 mounted on the measurement robot 2000 that is communicatively connected, thereby controlling the measurement sensor 22.

[0033] The measurement data acquisition unit 2414 acquires three-dimensional point cloud data of the first part 41 measured by the measurement sensor. The measurement data acquisition unit 2414 further transmits the acquired three-dimensional point cloud data to the cooperative control unit 2500. The calibration unit 2415 performs a predetermined calibration before work and associates the robot coordinate system and the sensor coordinate system with each other.

[0034] <Functions of the cooperative control unit 2500> 7 is a block diagram illustrating functions implemented in the cooperative control unit 2500. The cooperative control unit 2500 performs one of the characteristic processes of the manufacturing system 1000 of this embodiment. The manufacturing system 1000 of this embodiment includes: at least one measurement sensor 22 that measures the shape of each of multiple components that constitute an assembly; a shape data storage unit 2522 that stores the shape data of each component acquired by the measurement sensor 22; an assembly target component group selection unit 2514 that selects a first assembly target component group consisting of at least two components that will become components of the assembly from the multiple components; an assembly state estimation unit 2515 that estimates the assembly state of the assembly target component based on the shape data of the components belonging to the first assembly target component group; and an assembly execution command unit 2519 that issues an assembly execution command to the assembling robot 3000 to instruct the robot to assemble the assembly target component using the components included in the first assembly target component group based on the estimation result of the assembly state estimation unit 2515.

[0035] More specifically, the cooperative control unit 2500 has a processing unit 2510 and a storage unit 2520. The processing unit 2510 has a measurement condition determination unit 2511, a point cloud data acquisition unit 2512, a part suitability determination unit 2513, an assembly target part group selection unit 2514, an assembly state estimation unit 2515, an assembly permission determination unit 2516, an assembly non-permission determination unit 2517, a notification control unit 2518, and an assembly execution command unit 2519. The storage unit 2520 has a three-dimensional CAD data storage unit 2521, a shape data storage unit 2522, a tolerance allowable range storage unit 2523, a qualified part storage unit 2524, and a part to be assembled storage unit 2425.

[0036] The three-dimensional CAD data storage unit 2521 stores three-dimensional CAD data (three-dimensional shape data) which is design data of a measurement object to be measured by a measurement robot. When multiple types of parts are used as measurement objects, the three-dimensional CAD data storage unit 2521 stores three-dimensional CAD data (three-dimensional shape data) for each of the multiple types of parts.

[0037] The measurement condition determination unit 2511 acquires the three-dimensional CAD data of the measurement object corresponding to the identification information from the three-dimensional CAD data (three-dimensional shape data) of the measurement object stored in the three-dimensional CAD data storage unit 2521 based on the identification information of the measurement object input by the user from the input / output unit 1, and determines measurement conditions including the position and measurement direction (orientation of the measurement sensor 22) of the measurement sensor 22 that will perform the measurement based on the three-dimensional CAD data, and transmits the measurement conditions to the measurement control unit 2400.

[0038] The point cloud data acquisition unit 2512 acquires three-dimensional point cloud data as a measurement result of the measurement object from the measurement control unit 2400. Here, when acquiring three-dimensional point cloud data from multiple measurement control units 2400 or acquiring three-dimensional point cloud data from the measurement control units 2400 in multiple batches, the point cloud data acquisition unit 2512 integrates the acquired multiple pieces of three-dimensional point cloud data to generate integrated point cloud data of the measurement object. The three-dimensional point cloud data or integrated point cloud data acquired by the point cloud data acquisition unit 2512 is stored in the shape data storage unit 2522.

[0039] The tolerance allowable range storage unit 2523 stores in advance information about the tolerance allowable range of the measurement object, including the tolerance allowable range of each part (including the first part 41, the second part 42, and the third part) that is the measurement object, the tolerance allowable range of the primary assembly manufactured by assembling the first part 41 and the second part 42, and the tolerance allowable range of the secondary assembly manufactured by assembling the primary assembly and the third part. The user can input and update the information about the tolerance allowable range as needed using the input / output unit 1.

[0040] That is, the multiple parts in manufacturing system 1000 of this embodiment include a primary assembly formed by combining a first part and a second part, and a third part to be assembled to the primary assembly.

[0041] The manufacturing system 1000 of this embodiment includes a part suitability determination unit 2513 that determines for each part whether or not the part satisfies preset part suitability conditions based on the shape data, and an assembly target parts group selection unit 2514 selects a first assembly target parts group from at least two parts out of the multiple parts determined to be suitable by the part suitability determination unit.

[0042] The part suitability determination unit 2513 determines whether the shape of the measurement object falls within the tolerance allowance based on the tolerance allowance information stored in the tolerance allowance storage unit 2523 and the point cloud data of the measurement object acquired by the point cloud data acquisition unit 2512. If the shape does not fall within the tolerance allowance, it determines that the measurement object does not satisfy the suitability conditions as a part to be assembled, and conversely, if the shape of the measurement object falls within the tolerance allowance, it determines that the measurement object satisfies the suitability conditions as a part to be assembled. Identification information of parts determined to be suitable for assembly is stored in a qualified part storage unit 2524.

[0043] The assembly target component group selection unit 2514 selects an assembly target component group, which is a component group consisting of two or more components of a single or multiple types and is the target of assembly work. In this embodiment, an example of an embodiment will be described in which a primary assembly item is manufactured by assembling a first assembly target component group including a first component 41 and a second component 42, and a secondary assembly item is manufactured by assembling this primary assembly item with a first assembly target component group including a third component 43. Therefore, the assembly target component group selection unit 2514 selects two or more components that constitute the first assembly target component group. Furthermore, the assembly target component group selection unit 2514 selects the first assembly target component group from among multiple components based on information on multiple components determined to be appropriate for assembly, which is stored in the qualified component storage unit 2524. This configuration makes it possible to exclude inappropriate components, whose tolerances deviate from the allowable range, on a component-by-component basis from components to be assembled.

[0044] The assembly state estimation unit 2515 of the manufacturing system 1000 of this embodiment generates a three-dimensional model of the part based on the shape data, and simulates the shape of the assembly formed by assembling the first group of parts to be assembled, thereby estimating the assembly state when the first group of parts to be assembled is assembled.

[0045] The assembly state estimation unit 2515 acquires shape data of the parts corresponding to the first group of parts to be attached selected by the group of parts to be attached selection unit 2514 from the shape data (three-dimensional point cloud data) of each part stored in the shape data storage unit 2522, and estimates the assembly state when the first group of parts to be attached is assembled based on the shape data. As a more specific example, the assembly state estimation unit 2515 generates a three-dimensional model of each part that constitutes the first group of parts to be attached selected by the group of parts to be attached selection unit 2514 based on the recorded information in the shape data storage unit 2522, and estimates the assembly state when the first group of parts to be attached is assembled by simulating the shape of a device (primary assembly item, secondary assembly item, or product) formed by assembling the first group of parts to be attached based on the three-dimensional model. The shape data (three-dimensional point cloud data) of each part stored in the shape data storage unit 2522 is detailed enough to allow for grasping tolerances within the allowable range for errors in part shape that occur during the part manufacturing process, and therefore, before actually assembling the first group of parts to be assembled, it is possible to confirm by simulation the detailed shape of the equipment that will be formed by assembling the first group of parts to be assembled.

[0046] Here, even if the part suitability determination unit 2513 determines that the shape of the measurement object is within the tolerance range and that the measurement object satisfies the suitability conditions as a part to be assembled, each of the parts determined to be suitable will have a shape error within the tolerance range, and therefore, when the first group of parts to be assembled is actually assembled, the shape of equipment such as the primary assembly after assembly may end up deviating from the tolerance range of the equipment due to the influence of the shape error of each part.

[0047] The manufacturing system 1000 of this embodiment includes an assembly permission determination unit 2516 that determines whether the assembly state of the first group of parts to be assembled estimated by the assembly state estimation unit 2515 satisfies predetermined assembly permission conditions, and when the assembly permission determination unit 2516 determines that the assembly permission conditions are satisfied, the assembly execution command unit 2519 gives an assembly execution command to the assembly robot 3000 to execute the assembly work of the first group of parts to be assembled.

[0048] Furthermore, the assembly state estimation unit 2515 of the manufacturing system according to the first embodiment generates a three-dimensional model of the primary assembly based on shape data of the primary assembly formed by combining the first part and the second part included in the first group of parts to be assembled, generates a three-dimensional model of the third part based on shape data of the third part to be assembled with the primary assembly, and estimates the assembly state of the secondary assembly by simulating the shape of the secondary assembly formed by combining the third part with the primary assembly using the three-dimensional model of the primary assembly and the three-dimensional model of the third part.

[0049] The assembly permission determination unit 2516 determines whether the estimated shape data is within the tolerance range based on the estimated shape data of the equipment (primary assembly, secondary assembly, or product) after part assembly estimated by the assembly state estimation unit 2515 and the information on the tolerance range of the equipment stored in the tolerance range storage unit 2523, and permits assembly if the estimated shape data is within the tolerance range. Note that it is also possible to add conditions other than the upper limit of the tolerance range in which the estimated shape data is within the tolerance range as a condition for permitting assembly.

[0050] The manufacturing system 1000 of this embodiment includes an assembly non-permission determination unit 2517 that determines whether the assembly state of the first group of components to be assembled estimated by the assembly state estimation unit 2515 satisfies predetermined assembly non-permission conditions. When the assembly non-permission determination unit 2517 determines that the assembly non-permission conditions are met, the assembly target component group selection unit 2514 selects the components that satisfy the predetermined assembly permission conditions as the second group of components to be assembled, and the assembly execution command unit 2519 gives the assembly execution command to the assembly robot 3000 instructing it to assemble the assembly product using the components included in the second group of components to be assembled, instead of the first group of components to be assembled.

[0051] The assembly disapproval determination unit 2517 determines whether the estimated shape data is within the tolerance range based on the estimated shape data of the equipment (primary assembly, secondary assembly, or product) after part assembly estimated by the assembly state estimation unit 2515 and the information on the tolerance range of the equipment stored in the tolerance range storage unit 2523, and determines that the assembly is not permitted if the estimated shape data is outside the tolerance range. Note that it is also possible to add conditions other than the above-mentioned condition that the estimated shape data is outside the tolerance range as conditions for disapproving the assembly.

[0052] The manufacturing system 1000 of this embodiment includes a notification control unit 2518 that notifies the user of permission information for the assembly work of the first group of parts to be assembled when the assembly permission determination unit 2516 determines that the assembly permission conditions are met.

[0053] The notification control unit 2518 notifies the user of the determination result of the assembling permission determination unit 2516 or the assembling non-permission determination unit 2517. Specifically, the notification control unit 2518 notifies the user of the determination result via the output device of the input / output unit 1 by transmitting the determination result of the assembling permission determination unit 2516 or the assembling non-permission determination unit 2517 to the input / output unit 1.

[0054] When the assembly permission determination unit 2516 determines that assembly is permitted, the assembly execution command unit 2519 transmits an assembly execution command to the assembly control unit 2600 to execute the assembly of the combination of parts for which assembly has been permitted (for example, a first group of parts to be attached, etc.). Furthermore, the assembly execution command unit 2519 stores information on the combination of parts for which the assembly execution command has been issued (for example, a first group of parts to be attached, etc.) in the assembly part storage unit 2425.

[0055] If the assembly non-permission determination unit 2517 determines that the assembly of the first group of components to be attached is not permitted, the assembly target component group selection unit 2514 reselects a combination of components different from the first group of components to be attached. The assembly state estimation unit 2515 estimates the assembly state of the reselected combination of components when assembled, and if the assembly permission determination unit 2516 permits the assembly, the assembly target component group selection unit 2514 selects the combination of parts as a second group of components to be attached.

[0056] Information about the second group of components to be attached reselected by the group of components to be attached selection unit 2514 as described above is notified to the user by the notification control unit 2518, and an assembly execution command for assembling the second group of components to be attached is sent to the assembly control unit 2600 by the assembly execution command unit 2519.

[0057] <Functions of the assembly control unit 2600> 8 is a diagram showing an example of the functional configuration of the assembly control unit 2600. The assembly control unit 2600 includes an assembly execution command acquisition unit 2611, an arm control unit 2612, a welding torch control unit 2613, and a calibration unit 2415. The assembly execution command acquisition unit 2611 receives an assembly execution command from the cooperative control unit 2500, which instructs the execution of an assembly operation. The arm control unit 2612 generates an operation command for the arm 31 required for the assembly operation based on the assembly execution command, and transmits the operation command to the communicatively connected assembly robot 3000 to control the arm 31 of the assembly robot 3000. The welding torch control unit 2613 generates an operation command for the welding torch 32 required for the assembly operation based on the assembly execution command, and transmits the operation command to the welding torch 32 mounted on the communicatively connected assembly robot 3000 to control the welding torch 32. The calibration unit 2415 performs a predetermined calibration before the execution of the assembly work, and correlates the robot coordinate system and the torch coordinate system with each other.

[0058] Fig. 9 is a diagram showing an example of a manufacturing process using a manufacturing system. The example shown in Fig. 9 shows a manufacturing process in which the shapes of a first part 41 and a second part 42 are measured by a measuring robot 2000, the first part 41 and the second part 42 are assembled by an assembling robot 3000 to produce a primary assembly 4, and the shape of the primary assembly 4 is measured by the measuring robot 2000, and the primary assembly 4 and a third part 43 are assembled by the assembling robot 3000 to produce a secondary assembly 5.

[0059] <Process flow during manufacturing of primary assembly> Fig. 10 is a diagram showing an example of a processing flow when the manufacturing system in this embodiment manufactures a primary assembly using a first part and a second part. The operational flow shown in Fig. 10 illustrates the operational flow when the primary assembly is manufactured by assembling the first part 41 and the second part 42 in the manufacturing process shown in Fig. 9. First, in step 101, the measuring robot 2000 measures three-dimensional point cloud data of the first part 41 and the second part 42, which are the measurement targets, in accordance with the measurement conditions determined by the measurement condition determination unit 2511.

[0060] Next, in step 102, based on the shape data of the first part 41 and the second part 42 that have been actually measured, the suitability of the parts is determined based on criteria such as whether or not the shape error of each part is within the tolerance range.

[0061] Next, in step 103, the assembly target component group selection unit 2514 selects a first component 41 and a second component 42 from among the multiple components determined to be appropriate in the component suitability determination in step 102.

[0062] Next, in step 104, the assembly state estimation unit 2515 estimates the shape state after assembly when the first part 41 and the second part 42 are assembled. Specifically, based on each shape data obtained by actually measuring the first part 41 and the second part 42, a three-dimensional model of each part is generated, and the shape of the primary assembly formed by assembling the first part 41 and the second part 42 is estimated by simulation.

[0063] Next, in step 105, the assembly permission determination unit 2516 or the assembly non-permission determination unit 2517 determines whether or not the assembly of the first part 41 and the second part 42 is permitted based on predetermined determination criteria such as whether or not the shape of the primary assembly formed by assembling the first part 41 and the second part 42 falls within a predetermined tolerance allowable range. Next, in step 106, the determination result in step 105 is notified to the user via the input / output unit 1.

[0064] Next, in step 107, if the result of the determination as to whether or not the first part 41 and the second part 42 are to be assembled is "assembly permitted," the process proceeds to step 108, where an assembly work instruction is issued. On the other hand, if the result of the determination as to whether or not the first part 41 and the second part 42 are to be assembled is "assembly not permitted," the process returns to step 103, and processing is carried out from the selection of a group of parts to be assembled.

[0065] Next, in step 109, information on the first part 41 and the second part 42 for which the assembly work instruction was given in step 108 is stored in the assembly part storage unit 2425.

[0066] <Process flow when manufacturing secondary assemblies> 11 is a diagram showing an example of a processing flow when the manufacturing system in this embodiment manufactures a secondary attaché using a primary attaché and a third part. First, in step 201, the measuring robot 2000 measures three-dimensional point cloud data of the primary attaché and the third part 43, which are parts necessary for manufacturing the secondary attaché, in accordance with the measurement conditions determined by the measurement condition determination unit 2511.

[0067] Next, in step 202, based on the shape data of the actually measured primary assembly and the third part 43, the suitability of the parts is determined based on criteria such as whether or not the shape error of each part falls within the tolerance range.

[0068] Next, in step 203, the assembly target component group selection unit 2514 selects the primary assembly item and the third component 43 from among the multiple components determined to be appropriate in the component suitability determination in step 202.

[0069] Next, in step 210 , the shape data of the first and second parts that constitute the primary assembly selected by the assembly target parts group selection unit 2514 is acquired from the shape data storage unit 2522 .

[0070] Next, in step 204, the assembly state estimation unit 2515 estimates the shape state after assembly when the item for primary assembly and the third part 43 are assembled. Specifically, based on the shape data obtained by actually measuring the item for primary assembly and the third part 43 and the shape data of the first part and the second part that constitute the item for primary assembly, three-dimensional models of the item for primary assembly and the third part 43 are generated, and the shape of the item for secondary assembly formed by assembling the item for primary assembly and the third part 43 is estimated by simulation.

[0071] Here, because the primary assembly has a complex structure in which the first and second parts are assembled, it is difficult to measure the inner shape of the primary assembly or the shape of the contact surfaces between the first and second parts using a method of directly measuring the primary assembly using a measurement robot. Therefore, as described above, the assembly state estimation unit 2515 estimates the shape of the secondary assembly using not only the shape data obtained by actually measuring the primary assembly and the third part 43, but also the shape data of the first and second parts that make up the primary assembly. This makes it possible to more accurately estimate the shape of the secondary assembly, and improves the efficiency of the work of selecting a group of parts to be assembled to manufacture the secondary assembly.

[0072] The following steps 205 to 209 are the same as steps 105 to 109 in FIG. 10, and therefore the explanation will be omitted.

[0073] <Supplementary explanation for poor tolerance matching> 12, 13, and 14, an example will be described in which a problem occurs in the shape of a device after assembly when the tolerances of parts are poorly matched. FIG. 12 is a diagram showing an example of a primary assembly manufactured by a manufacturing system. In the example shown in FIG. 12, the primary assembly is composed of two first parts (41a, 41b) and three second parts 42. Of the two first parts, the first part located on the lower side of the primary assembly is designated 41a, and the first part located on the upper side is designated 41b.

[0074] 13 and 14 are diagrams showing assembly errors that occur in equipment manufactured by a manufacturing system. FIG. 13 shows a screw fastening portion between a first part 41a and a second part 42, which are located on the lower side. As shown in FIG. 13, the position of screw hole A on the first part 41a is shifted to the left from the ideal design position in the three-dimensional CAD data within the tolerance range, and screw hole B is shifted to the right from the ideal design position in the three-dimensional CAD data within the tolerance range. Therefore, the second part 42 is fixed in a position rotated clockwise relative to the first part 41a.

[0075] 14 also shows the screw fastening portion between the first part 41b located on the upper side and the second part 42. As shown in Fig. 14, the position of the screw hole C on the first part 41b is shifted to the right from the ideal design position on the three-dimensional CAD data within the tolerance range, and the screw hole D is shifted to the left from the ideal design position on the three-dimensional CAD data within the tolerance range. Therefore, the first part 41b is fixed at a position rotated clockwise relative to the second part 42.

[0076] If an error occurs within the tolerance range as described above, the relative position of first part 41a and first part 41b will be significantly twisted from the ideal design position, and will deviate from the tolerance allowable range of the primary assembly.

[0077] In this way, by estimating the shape and assembly state of the equipment after the parts have been assembled based on the shape data of each part to be assembled, it is possible to know in advance before the actual assembly work that the tolerances of the parts do not match well and the shape of the equipment after assembly will deviate from the tolerance allowable range of the specified equipment, and it becomes possible to select parts with good tolerance matching and perform the assembly work.

[0078] Although the present embodiment has been described above, the above embodiment is intended to facilitate understanding of the present invention and is not intended to limit the present invention. The present invention may be modified or improved without departing from the spirit thereof, and equivalents thereof are also included in the present invention.

[0079] This application claims priority based on Japanese Patent Application Nos. 2022-136035 and 2022-136036, filed on August 29, 2023, the disclosures of which are incorporated herein in their entireties.

[0080] Finally, the embodiments of the present invention will be summarized with reference to the drawings etc. The embodiments of the present invention will be described below with reference to Figs.

[0081] (Appendix 1) At least one measurement sensor (22) for measuring the shape of each of a plurality of components constituting the assembly; a shape data storage unit (2522) that stores shape data of the part acquired by the measurement sensor (22) for each part; an attachment target component group selection unit (2514) that selects a first attachment target component group consisting of at least two components that will become components of the assembly from among the plurality of components; an assembly state estimation unit (2515) that estimates an assembly state of the assembly based on the shape data of the components belonging to the first group of components to be assembled; an assembly execution command unit (2519) that issues an assembly execution command to the assembly robot (3000) to instruct the assembly of the object to be assembled using the parts included in the first group of parts to be assembled based on the result of the estimation by the assembly state estimation unit (2515); A manufacturing system comprising:

[0082] (Appendix 2) The manufacturing system of claim 1, wherein the plurality of parts includes a primary assembly formed by combining a first part and a second part, and a third part assembled to the primary assembly.

[0083] (Appendix 3) an assembly permission determination unit (2516) that determines whether or not the assembly state of the first group of assembly target parts estimated by the assembly state estimation unit (2515) satisfies a predetermined assembly permission condition; 3. The manufacturing system according to claim 1, wherein, when the assembly permission determination unit (2516) determines that the assembly permission conditions are met, the assembly execution command unit (2519) gives the assembly execution command to the assembly robot (3000) to perform the assembly work of the first group of parts to be assembled.

[0084] (Appendix 4) an assembly disapproval determination unit (2517) that determines whether or not the assembly state of the first group of assembly target parts estimated by the assembly state estimation unit (2515) satisfies a predetermined assembly disapproval condition; When the assembly non-permission determination unit (2517) determines that the assembly non-permission condition is satisfied, the assembly target component group selection unit (2514) selects the components that satisfy the predetermined assembly permission condition as a second assembly target component group, 4. The manufacturing system according to any one of appendices 1 to 3, wherein the assembly execution command unit (2519) issues the assembly execution command to the assembly robot (3000) to instruct the assembly of the object to be assembled using the parts included in the second group of parts to be assembled, instead of the first group of parts to be assembled.

[0085] (Appendix 5) The assembly state estimation unit (2515) generating a three-dimensional model of the part based on the shape data; 5. The manufacturing system according to claim 1, wherein the assembly state when the first group of assembly target parts is assembled is estimated by simulating the shape of the assembly formed by assembling the first group of assembly target parts.

[0086] (Appendix 6) the assembly state estimation unit (2515) generates a three-dimensional model of the primary assembly based on shape data of the primary assembly formed by combining a first part and a second part included in the first group of parts to be assembled; generating a three-dimensional model of a third part based on shape data of the third part to be combined with the primary assembly; the manufacturing system according to Appendix 5, wherein an assembled state of the secondary assembly is estimated by simulating a shape of a secondary assembly in which the primary assembly and the third part are combined using the three-dimensional model of the primary assembly and the three-dimensional model of the third part.

[0087] (Appendix 7) a part suitability determination unit (2513) that determines, for each of the parts, whether or not a preset compatibility condition for the part is satisfied based on the shape data; The manufacturing system according to any one of appendices 1 to 6, wherein the assembly target component group selection unit (2514) selects the first assembly target component group from at least two components out of a plurality of components determined to be suitable by the component suitability determination unit.

[0088] (Appendix 8) The manufacturing system according to claim 3, further comprising a notification control unit (2518) that notifies a user of permission information for the assembly work of the first group of parts to be assembled when the assembly permission determination unit (2516) determines that the assembly permission conditions are met.

[0089] (Appendix 9) 9. The manufacturing system according to any one of appendices 1 to 8, further comprising an assembly robot (3000) that performs assembly work on the first group of components to be assembled in accordance with the assembly execution command output by the assembly execution command unit (2519).

[0090] (Appendix 10) A control method for a manufacturing system that manufactures an assembly having a plurality of parts assembled thereto using an assembly robot (3000), comprising: For a plurality of components constituting an assembly, shape data of the components is acquired from the measurement results of the shapes of the components (101); The shape data is stored in a shape data storage unit for each of the parts (101); A first group of parts to be attached is selected from the plurality of parts, and the first group of parts to be attached is composed of at least two parts that will be parts of the assembly (103); Estimating an assembly state of the assembly based on the shape data of the components belonging to the first group of components to be assembled (104); Based on the result of the estimation, an assembly execution command is given to an assembly robot (3000) to instruct assembly of the assembly using the parts included in the first assembly target part group (108). A method for controlling a manufacturing system in which processing is executed in a computer.

[0091] (Appendix 11) A shape data acquisition process (101) for acquiring shape data of a plurality of parts constituting an assembly from the measurement results of the shape of each part; A shape data storage process (101) for storing the shape data for each part in a shape data storage unit; an assembly target component group selection process (103) for selecting a first assembly target component group consisting of at least two components that will become components of the assembly from among the plurality of components; an assembly state estimation process (104) for estimating an assembly state of the assembly based on the shape data of the components belonging to the first group of components to be assembled; an assembly execution command (108) for giving an assembly execution command to an assembly robot (3000) instructing the assembly of the object to be assembled using the parts included in the first group of parts to be assembled based on the result of the estimation; A control program that causes a computer to execute the above. [Explanation of symbols]

[0092] 1: Input / output unit, 2: Controller, 4: Primary assembly, 10: Processor, 11: Memory, 12: Storage, 13: Transmitter / receiver, 15: Bus, 21: Arm, 22: Measurement sensor, 23: Welding torch, 31: Arm, 32: Welding torch, 41: First part, 42: Second part, 43: Third part, 1000: Manufacturing system, 2000: Measurement robot, 2400: Measurement control unit, 2411: Measurement condition acquisition unit, 2412: Arm control unit, 2413: Measurement sensor control unit, 2414: Measurement data acquisition unit, 2415: Calibration unit, 2500: Collaboration control unit, 2510: Processing unit, 2511: Measurement Measurement condition determination unit, 2512: Point cloud data acquisition unit, 2513: Part suitability determination unit, 2514: Assembly target part group selection unit, 2515: Assembly state estimation unit, 2516: Assembly permission determination unit, 2517: Assembly non-permission determination unit, 2518: Notification control unit, 2519: Assembly execution command unit, 2520: Memory unit, 2521: 3D CAD data memory unit, 2522: Shape data memory unit, 2523: Tolerance allowable range memory unit, 2524: Eligible part memory unit, 2425: Assembly part memory unit, 2600: Assembly control unit, 2611: Assembly execution command acquisition unit, 2612: Arm control unit, 2613: Welding torch control unit, 3000: Assembly robot

Claims

1. At least one measurement sensor that measures the shape of each of a plurality of components that constitute an assembly; a shape data storage unit that stores the shape data of the part acquired by the measurement sensor for each of the parts; an assembly target component group selection unit that selects a first assembly target component group consisting of at least two components that will become components of the assembly from among the plurality of components; an assembly state estimation unit that estimates an assembly state of the assembly based on the shape data of the components that belong to the first group of components to be assembled; an assembly execution command unit that issues an assembly execution command to an assembly robot, the assembly execution command instructing the robot to assemble the object to be assembled using the components included in the first group of components to be assembled, based on the result of the estimation by the assembly state estimation unit; A manufacturing system comprising:

2. The manufacturing system according to claim 1 , wherein the plurality of parts includes a primary assembly formed by combining a first part and a second part, and a third part assembled to the primary assembly.

3. an assembly permission determination unit that determines whether or not the assembly state of the first group of assembly target parts estimated by the assembly state estimation unit satisfies a predetermined assembly permission condition, 2. The manufacturing system according to claim 1, wherein, when the assembly permission determination unit determines that the assembly permission conditions are satisfied, the assembly execution command unit issues the assembly execution command to an assembly robot to execute assembly work of the first group of assembly target parts.

4. an assembly disapproval determination unit that determines whether or not the assembly state of the first group of assembly target parts estimated by the assembly state estimation unit satisfies a predetermined assembly disapproval condition, When the assembly non-permission determination unit determines that the assembly non-permission condition is satisfied, the assembly target component group selection unit selects the components that satisfy a predetermined assembly permission condition as a second assembly target component group; 2. The manufacturing system according to claim 1, wherein the assembly execution command unit issues the assembly execution command to an assembly robot instructing the robot to assemble the object to be assembled using the parts included in the second group of parts to be assembled, instead of the first group of parts to be assembled.

5. The assembly state estimation unit generating a three-dimensional model of the part based on the shape data; 2. The manufacturing system according to claim 1, wherein an assembly state when the first group of assembly target parts is assembled is estimated by simulating a shape of the assembly formed by assembling the first group of assembly target parts.

6. the assembly state estimation unit generates a three-dimensional model of the primary assembly based on shape data of the primary assembly formed by combining a first part and a second part included in the first group of assembly target parts; generating a three-dimensional model of a third part based on shape data of the third part to be combined into the primary assembly; 6. The manufacturing system according to claim 5, wherein the assembled state of the secondary assembly is estimated by simulating a shape of a secondary assembly in which the primary assembly and the third part are combined using the three-dimensional model of the primary assembly and the three-dimensional model of the third part.

7. a part suitability determination unit that determines, for each of the parts, whether a preset compatibility condition for the part is satisfied based on the shape data; The manufacturing system according to claim 1 , wherein the assembly target component group selection unit selects the first assembly target component group from at least two components among the plurality of components determined to be suitable by the component suitability determination unit.

8. 4. The manufacturing system according to claim 3, further comprising a notification control unit that notifies a user of permission information for the assembly work of the first group of assembly target parts when the assembly permission determination unit determines that the assembly permission conditions are satisfied.

9. 2. The manufacturing system according to claim 1, further comprising an assembly robot that performs an assembly operation on the first group of components to be assembled in accordance with the assembly execution command output by the assembly execution command unit.

10. A control method for a manufacturing system that uses an assembly robot to manufacture an assembly having a plurality of parts assembled thereto, comprising: acquiring shape data of a plurality of parts constituting an assembly from measurement results of the shape of each part; storing the shape data for each of the components in a shape data storage unit; selecting a first group of parts to be attached, which is made up of at least two parts that will become parts of the assembly, from the plurality of parts; estimating an assembly state of the assembly based on the shape data of the components belonging to the first group of components to be assembled; Based on the result of the estimation, an assembly execution command is given to an assembly robot to instruct the assembly of the object to be assembled using the parts included in the first assembly target part group. A method for controlling a manufacturing system in which processing is executed in a computer.

11. a shape data acquisition process for acquiring shape data of a plurality of parts constituting an assembly from measurement results of the shapes of the parts; a shape data storage process for storing the shape data for each of the components in a shape data storage unit; an assembly target component group selection process for selecting a first assembly target component group consisting of at least two components that will become components of the assembly from among the plurality of components; an assembly state estimation process for estimating an assembly state of the assembly based on the shape data of the components belonging to the first group of components to be assembled; an assembly execution command that instructs an assembly robot to assemble the object to be assembled using the parts included in the first group of parts to be assembled based on the result of the estimation; and A control program that causes a computer to execute the above.

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