Robot system, robot system control method, and computer program

Abstract

A robot system (1) comprises: a processing tool (13) which processes a workpiece (100); an accommodation unit (11) which can accommodate the processing tool (13); a sensor (5) which detects a detection object that is previously set in a previously set detection area; and a control unit (3) which, in response to the sensor (5) detecting the detection object previously set in the detection area, accommodates the processing tool (13) in the accommodation unit (11).

Description

Technical Field

[0001] The present disclosure relates to a robot system, a robot system control method, and a computer program. Background Art

[0002] Conventionally, when manufacturing products through collaborative work between an operator and a robot, the work space of the operator and the robot is divided by arranging the robot inside a virtual safety fence, safety area or the like, and the robot is stopped when the operator enters the work space of the robot.

[0003] For example, in the robot system disclosed in Patent Document 1, trajectory calculation of the robot's workpiece, tool and the like in a three-dimensional space is performed, and control is performed so that the robot can stop within a virtual safety fence area. Prior Art Documents Patent Documents

[0004] Patent Document 1 Japanese Unexamined Patent Publication No. 2004-322244 Summary of the Invention Problems to be Solved by the Invention

[0005] However, when the robot merely stops, processing tools such as tools and kits attached to the arm of the robot are exposed, so other movable objects may interfere with the processing tool, which may cause breakage or damage to the processing tool.

[0006] The present disclosure has been made in view of the above circumstances, and an object of the present disclosure is to provide a robot system, a robot system control method, and a computer program that can suppress the risk of breakage or damage to a processing tool. Means for Solving the Problems

[0007] To achieve the above objective, the robot system according to this disclosure comprises a processing device for processing a workpiece, a housing capable of housing the processing device, a sensor for detecting a pre-set object in a pre-set detection area, and a control unit that houses the processing device in the housing in response to the sensor detecting a pre-set object in the detection area. The storage compartment is equipped with a door that can be opened and closed. The door opens in response to the action of exposing the processing equipment from the storage compartment and closes in response to the action of storing the processing equipment in the storage compartment. [Effects of the Invention]

[0008] According to this disclosure, when the sensor detects an object within the detection area, the processing device is housed in the housing. Therefore, damage to the processing device can be suppressed. [Brief explanation of the drawing]

[0009] [Figure 1] Perspective view showing a robot system according to Embodiment 1 of this disclosure [Figure 2] Diagram illustrating the configuration of the robot system according to Embodiment 1. [Figure 3A] A diagram showing the state in which the robot tool according to Embodiment 1 has housed the processing tool. [Figure 3B] A diagram showing the robot tool according to Embodiment 1 with the processing tool exposed. [Figure 4] Block diagram of the robot system according to Embodiment 1 [Figure 5] Flowchart showing robot tool control processing by the robot system according to Embodiment 1 [Figure 6A] Detailed diagram showing the robot tool according to Embodiment 2 of this disclosure in a state in which a processing tool is housed. [Figure 6B] Detailed diagram showing the robot tool according to Embodiment 2 with the processing tool exposed. [Figure 7A] This diagram illustrates the state in which the robot tool according to Embodiment 2 begins to expose the processing tool. [Figure 7B] This diagram illustrates the state in which the robot tool according to Embodiment 2 begins to house the processing tool. [Figure 8]Figure showing a state where a robot tool according to Embodiment 3 of the present disclosure accommodates a processing tool [Figure 9A] Figure illustrating a state where the robot tool according to Embodiment 3 starts exposing a processing tool [Figure 9B] Figure illustrating a state where the robot tool according to Embodiment 3 exposes a processing tool [Figure 10] Figure illustrating a state where the robot tool according to Embodiment 3 starts accommodating a processing tool [Figure 11] Figure illustrating the configuration of a robot system according to Embodiment 4 [Figure 12] Flowchart showing robot control processing in the robot system according to Embodiment 4 [Figure 13] Figure showing a state where a robot tool according to a modified example of the present disclosure accommodates a processing tool [Figure 14] Figure showing a state where a robot tool according to another modified example of the present disclosure accommodates a processing tool [Figure 15] Figure showing a state where a robot tool according to still another modified example of the present disclosure accommodates a processing tool [Figure 16A] Figure showing a state where a robot tool according to Embodiment 4 accommodates a processing tool [Figure 16B] Figure showing a state where a robot tool according to Embodiment 4 exposes a processing tool Description of Embodiments

[0010] Hereinafter, a robot system and a robot system control method according to embodiments of the present disclosure will be described with reference to the drawings. In the drawings, the same or equivalent portions are denoted by the same reference signs.

[0011] Furthermore, to facilitate understanding, we will establish a Cartesian coordinate system XYZ. In the Cartesian coordinate system XYZ shown in each figure, the direction of movement of the processing tool of the robot tool according to the embodiment, which will be described later, is the Y-axis direction, the direction in which the cylinder and the processing tool are aligned, which will be described later, is the X-axis direction, and the direction perpendicular to the Y-axis direction and the X-axis direction is the Z-axis direction. Hereafter, Embodiment 1 will be described by referring to this coordinate system as appropriate.

[0012] [Embodiment 1] The robot system according to Embodiment 1 manufactures products by working in collaboration with an operator to process a workpiece with a processing tool. In the robot system 1 shown in Figure 1, the robot tool 10 is designed to stop when the operator 200 enters the robot's work area beyond the human detection sensor 5. Furthermore, when the human detection sensor 5 detects that the operator 200 has entered the work area, the robot system 1 stores the processing tool 13 shown in Figure 2 in the storage unit 11.

[0013] (Configuration of Robot System 1) As shown in Figures 1 and 2, the robot system 1 includes a robot 2 equipped with a robot arm 6 to which a robot tool 10 is attached, a controller 3 that controls the movement of the robot 2, and a human detection sensor 5 that detects the movement of a worker 200.

[0014] Robot 2 is a 6-degree-of-freedom vertical articulated robot that works in cooperation with operator 200 to process workpiece 100. A robot tool 10 is mounted on the flange 9 of robot arm 6 of robot 2.

[0015] As shown in Figures 3A and 3B, the robot tool 10 includes a housing 11 for housing the processing tool 13, a cylinder 12 for exposing the processing tool 13 from the housing 11, the processing tool 13 for processing the workpiece 100, and an elastic member 14 for biasing the processing tool 13 in the direction of housing it in the housing 11.

[0016] The housing section 11 comprises a main body section 15 that houses the base of the processing tool 13, the cylinder 12, the elastic member 14, the monitoring sensor 40, etc., and a small-diameter section 17 that houses and exposes the tip of the processing tool 13. The housing section 11 houses the processing tool 13 in its internal space, isolating the processing tool 13 from the operator 200. The small-diameter section 17 is provided in communication with the opening 16 of the main body section 15, and exposes or houses the tip of the processing tool 13. The housing section 11 has sufficient strength and size to prevent damage, soiling, distortion, etc. of the housing tool 13 even if it comes into contact with or collides with tools, cleaning equipment, the operator 200, etc. The housing section 11 is attached to the flange 9 of the robot arm 6.

[0017] The opening 16 is provided at the -Y end of the main body 15. The opening 16 is provided with a funnel-shaped small-diameter section 17 through which the processing tool 13 can move forward and backward. The small-diameter section 17 has an outer diameter slightly larger than the outer diameter of the processing tool 13. As shown in Figure 3A, when the processing tool 13 is housed in the housing section 11, the tip of the processing tool 13 is housed in the small-diameter section 17.

[0018] Cylinder 12 is an air cylinder and is located within the housing 11. Under the control of the tool control unit 31, cylinder 12 extends the rod's protrusion amount using pressurized air supplied via the solenoid valve 8. When the rod is extended, cylinder 12 presses the connecting plate 18 connected to the processing tool 13 in the -Y direction, thereby exposing the tip of the processing tool 13 from the housing 11. Hereinafter, "exposing the tip of the processing tool 13 from the housing 11" will be referred to as "exposing the processing tool 13 from the housing 11".

[0019] The solenoid valve 8, under the control of the controller 3, opens the valve and supplies pressurized air, which is the power source, thereby extending the rod of the cylinder 12. The solenoid valve 8, under the control of the controller 3, also stops the supply of pressurized air and exhausts the pressurized air inside the cylinder 12, thereby shortening the amount the rod protrudes.

[0020] The processing tool 13 is a tool for processing the workpiece, and can be any tool capable of processing the workpiece, such as a soldering iron, screwdriver, cutting tool, mounter, dispenser, etc. In the following description, we will assume that the processing tool 13 is a soldering iron as an example. The processing tool 13 is located in the housing section 11 by being connected to the cylinder 12 via a connecting plate 18. The processing tool 13 is exposed from the housing section 11 and is also housed in the housing section 11. The processing tool 13 can process the workpiece 100 by having its tip exposed from the housing section 11.

[0021] The elastic member 14 is, for example, a tension spring and is located within the housing 11. The elastic member 14 biases the connecting plate 18 in the direction that houses the processing tool 13. The cylinder 12 and the elastic member 14 function as a moving part for moving the processing tool 13.

[0022] The connecting plate 18 is an L-shaped member when viewed in the Z-axis direction. The connecting plate 18 connects the processing tool 13, the cylinder 12, and the elastic member 14. The connecting plate 18 includes a reciprocating mechanism connecting portion 18A connected to the tip of the rod of the cylinder 12 and one end of the elastic member 14, and a processing tool mounting portion 18B fixed to the reciprocating mechanism connecting portion 18A and to which the processing tool 13 is attached. The reciprocating mechanism connecting portion 18A and the processing tool mounting portion 18B may be formed integrally.

[0023] The monitoring sensor 40 detects that the processing tool 13 is in the storage position, which is when it is housed in the storage section 11. The monitoring sensor 40 is, for example, a microswitch, which is fixed in a position where the processing tool 13 makes contact when the rod of the cylinder 12 is in the shortened state, and transmits an ON signal to the controller 3.

[0024] Controller 3 has a computer equipped with a CPU (Central Processing Unit), a programmable controller (PLC), etc., and processes the workpiece by executing computer programs stored in memory units 32A and 32B, thereby realizing functions such as the robot control unit 30 and tool control unit 31, which will be described later. As shown in Figure 4, Controller 3 includes a robot control unit 30 and a tool control unit 31. The robot control unit 30 controls the movement of the robot arm 6 of the robot 2. The tool control unit 31 is, for example, a programmable controller and a solenoid valve 8, and controls the operation of the robot tool 10 of the robot 2 depending on whether or not a worker 200 is detected by the human detection sensor 5.

[0025] The memory units 32A and 32B include memory such as ROM (Read Only Memory) and RAM (Random Access Memory). Part or all of the ROM is composed of electrically rewritable memory, such as flash memory. The ROM stores the CPU of the controller 3, the program executed by the programmable controller, and the data necessary for executing the program. The RAM stores data created during program execution, modified data, etc. In this embodiment, the robot control unit 30 uses memory unit 32A and the tool control unit 31 uses memory unit 32B, but the memory units may be common to both.

[0026] The controller 3 is equipped with an input interface (hereinafter referred to as input I / F) 33 and an output interface (hereinafter referred to as output I / F) 34 for sending and receiving data with external devices. The input I / F 33 receives data from the human detection sensor 5 and the robot arm 6 and transmits it to the controller 3. The output I / F 34 transmits the control signals output by the controller 3 to the robot arm 6, solenoid valve 8, robot tool 10, etc.

[0027] A teach pendant (not shown) instructs the robot 2, via online or offline teaching, on the conditions, sequence, and orientation under which to process the workpiece 100. The teach pendant includes an emergency stop button, display unit, enable switch, and operating axis keys.

[0028] As shown in Figure 1, the human detection sensors 5 are erected at two corners on the side of the workbench 7 where the worker 200 works. The human detection sensors 5 include, for example, a light curtain with an interlock function, and detect when the worker 200 enters the robot work area on the workbench 7. The human detection sensors 5 are connected to the tool control unit 31 by a sensor signal line 35, and transmit the entry of the worker 200 to the controller 3.

[0029] A workpiece 100, which is to be processed, is placed on the workbench 7, and the workpiece 100 is fixed in place by a jig (not shown). The workbench 7 is the work area of ​​the robot 2. When any part of the worker 200's body enters the workbench 7, the human detection sensor 5 detects this, and the controller 3 stops the robot 2 and stores the processing tool 13 in the storage unit 11.

[0030] (Robot tool control) Next, the robot tool control performed when processing the workpiece 100 in the robot system 1 will be explained with reference to Figure 5. In the robot system 1, when processing the workpiece 100, a main process (not shown) that operates the robot 2, including the processing tool 13 and the robot arm 6, is executed in parallel with the robot tool control. In the main process, the robot control unit 30 processes the workpiece 100 using the processing tool 13. Furthermore, when the processing of the workpiece 100 is completed, or when the human detection sensor 5 detects that a worker 200 has entered the work area, the robot control unit 30 stops the movement of the robot arm 6.

[0031] When the robot system 1 is started, the tool control unit 31 starts the robot tool control process shown in Figure 5 and performs an initial setup process (step S101). In this initial setup process, the tool control unit 31 controls the solenoid valve 8 to exhaust the inside of the cylinder 12 and sets the processing tool 13 to a retracted state. When the tool control unit 31 receives ON data from the monitoring sensor 40, it determines that the processing tool 13 has been retracted.

[0032] Next, the tool control unit 31 determines whether or not at least a part of the worker's body has entered the work area based on the output data of the human detection sensor 5 (step S102).

[0033] If the human detection sensor 5 detects that at least part of the worker 200's body has entered the work area (step S102: Yes), the process returns to step S102. Therefore, the processing tool 13 remains in place.

[0034] If it is determined that the worker 200's body has not entered the work area (Step S102: No), the tool control unit 31 controls the solenoid valve 8 to supply pressurized air to the cylinder 12, exposing the processing tool 13 from the housing 11, and enabling the processing of the workpiece 100 to begin (Step S103). Thereafter, the processing of the workpiece 100 is performed as appropriate in the main process.

[0035] Next, the tool control unit 31 communicates with the robot control unit 30 to receive data indicating the progress of the machining operation on the workpiece 100 and determines whether the machining operation is complete or not (step S104). If the machining operation on the workpiece 100 is complete (step S104: Yes), the tool control unit 31 controls the solenoid valve 8 to exhaust the pressurized air in the cylinder 12 and retracts the elastic member 14 to house the machining tool 13 in the housing 11 (step S105). On the other hand, if the machining operation on the workpiece 100 is not complete (step S104: No), the process proceeds to step S107.

[0036] In step S106, it is determined whether the processing tool 13 can be accommodated in the storage unit 11 by whether the monitoring sensor 40 outputs ON data. If the processing tool 13 can be accommodated in the storage unit 11 (step S106: Yes), the operation of the robot system 1 is terminated. If the processing tool 13 cannot be accommodated in the storage unit 11 (step S106: No), the process returns to step S105 and attempts to accommodate the processing tool 13 again.

[0037] In step S107, the human detection sensor 5 determines whether at least a part of the worker 200's body has entered the work area. If at least a part of the worker 200's body has entered the work area (step S107: Yes), the tool control unit 31 controls the solenoid valve 8 to remove the air from the cylinder 12 and house the processing tool 13 in the housing 11 (step S108). At this time, in the main process, the robot control unit 30 stops the movement of the robot arm 6.

[0038] Next, the tool control unit 31 determines whether the processing tool 13 can be accommodated in the storage unit 11 based on whether the output data of the monitoring sensor 40 is on or off (step S109). If the processing tool 13 cannot be accommodated in the storage unit 11 (step S109: No), the process returns to step S108 and attempts to accommodate the processing tool 13 again.

[0039] If it is determined in step S109 that the processing tool 13 can be stored in the storage unit 11 (step S109: Yes), the output data of the human detection sensor 5 is used to determine whether at least a part of the worker 200's body has entered the work area. If it is determined that at least a part of the worker 200's body has entered the work area (step S110: Yes), the process returns to step S110. The process in step S110 is repeated until the worker 200's body leaves the work area. If the worker 200's body leaves the work area and the human detection sensor 5 no longer detects a person in the work area (step S110: No), the process returns to step S103.

[0040] When worker 200 leaves the work area and the human detection sensor 5 no longer detects a person in the work area (step S107: No), the process returns to step S104.

[0041] Thus, according to the robot system 1 of this embodiment, when at least a part of the worker 200's body is in the work area, the processing tool 13 is not exposed from the housing 11, or the processing tool 13 is housed in the housing 11. Therefore, the possibility of interference between the worker 200 and the processing tool 13 can be further reduced. As a result, damage to the processing tool 13 can be suppressed, and consequently, a decrease in work efficiency can be prevented.

[0042] [Embodiment 2] In Embodiment 1, the tip of the processing tool 13 is housed in the small-diameter section 17 to isolate the processing tool 13 from the work area, but the method of isolation is arbitrary. In Embodiment 2, as shown in Figures 6A and 6B, the processing tool 13 is isolated from the work area by a door 20 placed in the opening 16 of the housing section 11.

[0043] In Embodiment 2, the housing section 11 includes a main body section 15 that houses the processing tool 13, cylinder 12, elastic member 14, etc., and a door 20 that opens and closes in conjunction with the movement of the processing tool 13 in and out of the housing section 11.

[0044] Door 20 is open when the workpiece 13 is exposed from the housing 11, and when it is exposed, and is closed when the workpiece 13 is housed in the housing 11. Door 20 is movably positioned along the opening 16 in order to close the opening 16. A rack gear 22 is mounted on the inner surface of the housing 11 of door 20. A gear 24 that meshes with the rack gear 22 is rotatably mounted inside the housing 11. These function as a door drive unit that opens and closes door 20 in accordance with the movement of the workpiece 13.

[0045] A rack gear 21 is attached to the rack gear mounting portion 18C of the connecting plate 18. Inside the housing portion 11, a gear 23 that meshes with the rack gear 21 and gear 24 is rotatably mounted.

[0046] The rack gears 21, 22 and gears 23, 24 cause the door 20 to open when the processing tool 13 is exposed from the storage compartment 11, and to close when the processing tool 13 is stored in the storage compartment 11.

[0047] In Embodiment 2, as in Embodiment 1, the tool control unit 31 performs the same robot tool control as shown in the flowchart of Figure 5. The opening and closing operation of the door 20 will now be described. As in Embodiment 1, when the robot system 1 processes the workpiece 100, a main flow (not shown) that operates the robot 2, including the processing tool 13, is executed in parallel with the robot tool control.

[0048] (The action of opening door 20) As shown by arrow A in Figure 7A, in step S103 of Figure 5, the tool control unit 31 supplies air to the cylinder 12 to extend the rod and move the connecting plate 18 and the workpiece 13 in the -Y direction. The movement of the connecting plate 18 in the -Y direction causes the rack gear 21 to move in the -Y direction, and the gear 23 rotates in the direction shown by arrow B.

[0049] The rotation of gear 23 causes gear 24, which meshes with gear 23, to rotate in the direction of arrow C. This causes rack gear 22, which meshes with gear 24, to move in the direction of arrow D, and the door 20 to which the rack gear 22 is attached begins to open. Subsequently, as shown in Figure 6B, the processing tool 13 is exposed from the housing 11, and processing work becomes possible. By adjusting the overall length, number of teeth, and mounting position of rack gears 21 and 22, and the diameter, number of teeth, and mounting position of gears 23 and 24, the processing tool 13 is configured not to come into contact with the door 20 when the door 20 opens.

[0050] (The action of closing door 20) As shown by arrow E in Figure 7B, the tool control unit 31 deflates the air from the cylinder 12 in steps S105 and S108 of Figure 5, moving the connecting plate 18 and the workpiece 13 in the +Y direction. As the connecting plate 18 moves, the rack gear 21 moves in the +Y direction, causing the gear 23 to rotate in the direction indicated by arrow F.

[0051] The rotation of gear 23 causes gear 24, which meshes with gear 23, to rotate in the direction of arrow G. This causes rack gear 22, which meshes with gear 24, to move in the direction of arrow H and +X, and the door 20 to which the rack gear 22 is attached begins to close. Subsequently, as shown in Figure 6A, the door 20 closes and the processing tool 13 is housed in the storage section 11, and the processing tool 13 is isolated within the storage section 11.

[0052] Thus, according to the robot system 1 of the second embodiment, when the processing tool 13 is housed in the housing section 11, the opening 16 of the housing section 11 is closed by the door 20, and the processing tool 13 is more securely isolated from the work area.

[0053] [Embodiment 3] In Embodiment 2, the door 20 is opened and closed in accordance with the movement of the processing tool 13 using a rack and pinion. Embodiment 3 differs from Embodiment 2 in that, as shown in Figures 8 to 10, the door 20 is opened and closed in accordance with the movement of the processing tool 13 using a link mechanism attached to the connecting plate 18 and the door 20.

[0054] Door 20 is attached to the end of the opening 16 via a hinge 25 so as to be able to open and close. A cam follower 26 is attached to a cam follower mounting portion 18D formed at the -Y end of the connecting plate 18. The cam follower 26 is movably attached to the hollow portion 27A of a hollow oval cam 27. One end of a link 28 is rotatably attached to the -Y end of the cam 27. One end of a link 29 is rotatably attached to the other end of the link 28. Door 20 is attached to the other end of the link 29 so as to be able to open and close. The link mechanism 19 functions as a door drive unit that opens and closes door 20 in accordance with the movement of the workpiece 13.

[0055] In Embodiment 3, as in Embodiment 2, the tool control unit 31 performs the same robot tool control as in the flowchart of Figure 5. In step S103 of Figure 5, the door 20 is opened, and in steps S105 and S108, the door 20 is closed. The opening and closing operation of the door 20 will be described below. As in Embodiment 1, when the robot system 1 processes the workpiece 100, a main flow (not shown) that operates the robot 2 including the processing tool 13 is executed in parallel with the robot tool control.

[0056] (The action of opening door 20) As shown by arrow P in Figure 9A, the tool control unit 31 extends the rod of the cylinder 12 to move the connecting plate 18 and the workpiece 13 in the -Y direction. The movement of the connecting plate 18 causes the cam follower 26 to move the hollow portion 27A of the cam 27 in the -Y direction. At this time, the area near the center of the cam 27 is pressed by the bent portion 18E of the connecting plate 18, causing the -Y end of the cam 27 to move in the direction of arrow Q.

[0057] As shown in Figures 9A and 9B, when the -Y end of the cam 27 moves in the direction of arrow Q, links 28 and 29 move in the direction of arrow Q and rotate as shown by arrow R. The rotation of link 29 also causes the door 20 to rotate in the direction of arrow R, opening the door 20 and exposing the processing tool 13 from the housing 11. By adjusting settings such as the size of the cam follower mounting portion 18D, the mounting position of the cam follower 26, the total length of the cam 27, the shape of the hollow portion 27A, and the total length and mounting position of links 28 and 29, the processing tool 13 does not come into contact with the door 20 when the door 20 is opened.

[0058] (The action of closing door 20) As shown by arrow S in Figure 10, the movement of the head of the cylinder 12 or the -Y end of the elastic member 14 in the +Y direction causes the connecting plate 18 and the processing tool 13 to move in the +Y direction. As the cam follower 26 moves in the +Y direction in accordance with the connecting plate 18, the -Y end of the cam 27 moves in the direction of arrow T.

[0059] As the -Y end of cam 27 moves in the direction of arrow T, links 28 and 29 move in the direction of arrow T and rotate in the direction indicated by arrow U. Also, the door 20 to which link 29 is rotatably attached rotates in the direction of arrow U, causing the door 20 to begin closing. After the processing tool 13 is housed in the storage section 11, the door 20 is closed, resulting in the state shown in Figure 8.

[0060] Thus, according to the robot system 1 of Embodiment 3, when the processing tool 13 is housed in the housing section 11, the opening 16 of the housing section 11 is closed by the door 20, and the processing tool 13 is more securely isolated from the work area.

[0061] [Embodiment 4] In Embodiment 1, one detection area is set for the robot system 1. In contrast, in the robot system 1 of Embodiment 4, as shown in Figure 11, three detection areas R1, R2, and R3 are set for the work area of ​​the robot arm 6 and its surrounding area. The three detection areas R1, R2, and R3 each include the working area and surrounding range of the robot arm 6 for workpieces 101, 102, and 103, respectively. Furthermore, if the robot system 1 detects an operator 200 in one of the detection areas R1, R2, or R3, which includes the working area where the robot arm 6 is performing machining, it moves the robot arm 6 to another detection area to perform machining on the workpiece 100.

[0062] The robot system 1 has human detection sensors 51, 52, and 53. The human detection sensors 51, 52, and 53 are reflective sensors such as area scan sensors and safety laser scanners. The human detection sensors 51, 52, and 53 are sensors that can detect a worker 200 as a single plane, ranging from an area close to the robot 2 to an area a certain distance away from the robot 2. Human detection sensor 51 detects when a worker 200 enters detection area R1. Human detection sensor 52 detects when a worker 200 enters detection area R2. Human detection sensor 53 detects when a worker 200 enters detection area R3.

[0063] The robot system 1 processes workpiece 101 located in detection area R1, workpiece 102 located in detection area R2, and workpiece 103 located in detection area R3 in order according to a preset processing sequence. Note that the processing tools 13 used for processing may differ for each workpiece. In this case, for example, the robot arm 6 may be equipped with multiple processing tools 13 at its tip and switch between processing tools 13 for each workpiece. Alternatively, the processing tools 13 may be interchangeable, similar to a machine tool, and the processing tools may be changed according to the workpiece. In the following description, the same processing tool 13 will be used for all workpieces. Also, in this embodiment, the robot arm 6 may be equipped with any of the robot tools 10 from Embodiments 1-3.

[0064] The robot control unit 30 has a motion change function. The motion change function is a function that, when an operator 200 enters any of the detection areas R1, R2, or R3, and the robot arm 6 was performing a processing operation within the detection area where the operator 200 was detected, stores the processing tool 13 in the storage unit 11 and moves the robot arm 6 to a detection area other than the detection area where the operator 200 has not entered.

[0065] The memory unit 32A stores the processing order of the workpieces 100. The robot system 1 processes the workpieces 100 according to the stored processing order. Based on this processing order, the robot control unit 30 identifies the workpiece 100 that is the first to be processed among the unprocessed workpieces 100. The processing order of the workpieces 100 may be stored in the robot system 1 in advance, or it may be set by the operator 200, or by a manager, user, etc. In the following explanation, the processing order will be assumed to be workpiece 101 → 102 → 103 → 101...

[0066] (Robot control) The robot control performed in the robot system 1 shown in Figure 11 will be explained with reference to Figure 12.

[0067] When the robot system 1 is started, the robot control unit 30 and the tool control unit 31 start the robot control process shown in Figure 12, and in addition to the same process as step S101 shown in Figure 5 of Embodiment 1, they perform initial setup processing to confirm the number and position of the detection area, the position of the workpiece 100, etc. (step S201).

[0068] In step S202, the robot control unit 30 refers to the memory unit 32A to confirm the processing order of the workpieces 100 and controls the robot arm 6 to move to the work area where the workpiece 100 with the earliest processing order is located. In the initial state, the robot arm 6 is moved to the processing area where workpieces 101 will be processed according to the processing order. If there are workpieces 100 that have been processed, the workpiece 100 with the earliest processing order is determined excluding the workpieces 100 that have been processed. Also, if an operator 200 enters a detection area where a workpiece 100 that is being processed is located, the workpiece 100 with the earliest processing order is determined excluding the workpiece 100 located in the detection area entered by the operator 200.

[0069] Next, in step S203, the output data of the human detection sensor 5 determines whether the worker 200 has entered the detection area, which includes the work area from which the robot arm 6 has moved to perform the machining operation. For example, if machining work on workpiece 101 is being performed, the detection area R1 is used to determine whether the worker 200 has entered the detection area, which includes the work area from which the robot arm 6 has moved (step S203: No). If the worker 200 has not entered the detection area, which includes the work area from which the robot arm 6 has moved (step S203: No), the tool control unit 31 exposes the machining tool 13 from the housing 11, making it possible to start machining work on workpiece 100 (step S204). Thereafter, in the main processing, machining work on workpiece 100 is performed as appropriate. If the human detection sensor 5 detects that at least a part of the worker 200's body has entered the detection area, which includes the work area from which the robot arm 6 has moved (step S203: Yes), the process returns to step S203.

[0070] In step S205, the tool control unit 31 determines whether the machining operation of the workpiece 100 is complete. If the machining operation of the workpiece 100 is complete (step S205: Yes), the process proceeds to step S206. If the machining operation of the workpiece 100 is not complete (step S205: No), the process proceeds to step S209.

[0071] In step S206, the robot control unit 30 determines whether the machining work on all workpieces 100 has been completed. If the machining work on all workpieces 100 has been completed (step S206: Yes), the robot control unit 31 is controlled to store the machining tool 13 in the storage unit 11 (step S207). If the machining work on one or more workpieces 100 has not been completed (step S206: No), the process returns to step S202.

[0072] In step S208, it is determined whether or not the processing tool 13 can be accommodated in the storage section 11. If the processing tool 13 can be accommodated in the storage section 11 (step S208: Yes), the operation of the robot system 1 is terminated. If the processing tool 13 cannot be accommodated in the storage section 11 (step S208: No), the process returns to step S207, and the attempt to accommodate the processing tool 13 is made again.

[0073] In step S209, the human detection sensor 5 determines whether at least a part of the worker 200's body has entered the detection area, which includes the work area where the robot arm 6 is working. For example, if the robot arm is performing a machining operation on a workpiece 101, the human detection sensor 5 determines whether at least a part of the worker 200's body has entered the detection area R1. If at least a part of the worker 200's body has entered the detection area (step S209: Yes), the tool control unit 31 controls the solenoid valve 8 to house the machining tool 13 in the storage unit 11 (step S210). At this time, in the main process, the robot control unit 30 stops the movement of the robot arm 6.

[0074] Next, the tool control unit 31 determines whether or not the processing tool 13 can be accommodated in the storage unit 11 (step S211). If the processing tool 13 cannot be accommodated in the storage unit 11 (step S211: No), the process returns to step S210 and attempts to accommodate the processing tool 13 again.

[0075] If the processing tool 13 is housed in the storage unit 11 in step S211 (step S211: Yes), the process returns to step S202. Here, the robot control unit 30 moves the robot arm 6 to a processing area where the next workpiece 100 in the processing sequence will be processed, and where it has been determined that no worker 200 has entered, according to the processing sequence. For example, if workpiece 101 has been processed and a worker is detected in detection area R1, the robot arm 6 moves to detection area R2. If a worker 200 is also detected in detection area R2, the robot arm 6 waits until a worker is no longer detected in the subsequent step S203. Similarly, for example, if workpiece 103 has been processed and a worker is detected in detection area R3, the robot arm 6 moves to detection area R1. If a worker 200 is also detected in detection area R1, the robot arm 6 waits until a worker is no longer detected in the subsequent step S203.

[0076] Furthermore, it is desirable to determine whether or not a worker 200 is detected in any of the other detection areas that the robot arm 6 will pass through as it moves, before the robot arm 6 moves to another work area, and to move the robot arm 6 only if no worker 200 is detected.

[0077] Thus, according to the robot system 1 of this embodiment, when an operator 200 enters a detection area that includes the work area where the robot arm 6 is working, the system can move on to processing another workpiece 100 without waiting for the operator 200 to move out of the detection area, thereby reducing downtime. Consequently, the processing efficiency of the workpiece 100 can be improved.

[0078] [Differentiation] In the embodiments described above, a soldering iron is used as an example of the processing tool 13, but the processing tool is arbitrary and may be a screwdriver, ratchet, cutting tool, electrical discharge machine, or other processing tool. The processing tool 13 may also be replaceable. Furthermore, in this disclosure, the objects housed and isolated by the housing section 11 may be processing tools that perform various processes on a workpiece, including processing. For example, various processing tools that perform processes on a workpiece can be used, such as nozzles that dispense cleaning fluid or paint onto a workpiece, or heads that vacuum-suction a workpiece.

[0079] In each of the above embodiments, the human detection sensor 5 was attached to the workbench 7, but it may also be attached to the robot arm 6, or to the storage unit 11, or to the processing tool 13.

[0080] Furthermore, in embodiments 1-3 described above, the human detection sensor 5 was an intrusion detection sensor using a light curtain, but it may also be a presence detection sensor. Alternatively, a pallet-type sensor may be installed on the floor near the robot 2, or a surveillance camera-type sensor may be installed, or a combination of these may be used. The human detection sensor 5 may also be the one described in embodiment 4. The human detection sensor 5 of embodiment 4 may also be the human detection sensor 5 of embodiments 1-3, or one of the sensors described above, or any other sensor. As for the surveillance sensor 40, the type of sensor and its mounting position are not limited as long as it can detect the movement of the processing tool 13.

[0081] Furthermore, while the human detection sensor 5 was used as an example, the objects to be detected can be arbitrary. For example, the arms and tools of other robots, transport equipment, tools used by workers, etc., may also be used as detection targets. The type of sensor will be appropriately selected depending on the type of object to be detected.

[0082] In embodiments 1-3 described above, the detection area for the target of detection was the work area of ​​the robot arm 6, but it is possible to arbitrarily set which area to be used as the detection area for the target of detection. For example, as with the detection areas R1, R2, and R3 in embodiment 4, the detection area may include the movable range of the robot arm 6 and a certain surrounding area. Alternatively, a part of the movable range of the robot arm 6, such as the exclusion area R4 shown in Figure 11, may be excluded from the detection area. Furthermore, the number of detection areas and sensors may also be any number.

[0083] The tool control unit 31 may be configured to emit a warning sound by sounding a speaker and flash a warning light when it detects that the worker 200 has entered the work area in steps S102, S107, and S110. This can encourage the worker 200 to quickly leave the work area, reduce the interruption time of the workpiece 100 processing, and improve the work efficiency of the robot system 1. The alarm processing may also be performed in the main processing.

[0084] Furthermore, in each of the above embodiments, the robot tool 10 moved the processing tool 13 to house the processing tool 13 in the housing section 11 and expose it from the housing section 11. However, as shown in Figure 15, for example, the processing tool 13 may be housed in the housing section 11 and exposed from the housing section 11 by moving the tip 41 of the housing section 11 in the Y-axis direction using a drive device 42 without moving the processing tool 13, or the entire housing section 11 may be moved. Alternatively, as shown in Figures 16A and 16B, a hinge 44 may open and close at the -Y-direction end of the tip 41 of the housing section 11 in accordance with the movement of the tip 41 in the Y-axis direction, thereby opening and closing a double door 43 to house and expose the processing tool 13. The robot tool 10 closes the door 43 while housing the processing tool 13 in the housing section 11 by moving the tip 41 in the -Y direction using a drive device 42, and opens the door 43 while exposing the processing tool 13 from the housing section 11 by moving the tip 41 in the +Y direction. Alternatively, the processing tool 13 may be housed in the storage section 11 and exposed from the storage section 11 by moving the storage section 11 and the processing tool 13, as long as the insertion and removal of the processing tool 13 from the storage section 11 can be achieved by the relative movement of the storage section 11 and the processing tool 13.

[0085] In each of the above embodiments, the robot system 1 is capable of resuming processing of the workpiece 100 after the worker 200 has entered the work area and is no longer detected in the work area. The robot system 1 may also be stopped temporarily.

[0086] In each of the embodiments described above, robot 2 was a vertical articulated collaborative robot with 6 degrees of freedom, but the type of robot is arbitrary. For example, it may be a horizontal articulated collaborative robot with 5 degrees of freedom or less. Alternatively, it may be another type of collaborative robot such as a vertical articulated collaborative robot with 7 or more degrees of freedom, a dual-arm collaborative robot, or a parallel-link collaborative robot.

[0087] In the embodiments described above, the processing tool 13 was exposed from the housing 11 by the cylinder 12, but other actuators such as electric cylinders, hydraulic cylinders, electromagnetic solenoids, linear motors, and motors may be used to move the processing tool. Also, although the processing tool 13 was housed in the housing 11 by the elastic member 14, it may also be housed in the housing 11 by the cylinder 12, or by other actuators.

[0088] In the embodiments described above, the elastic member 14 was a tension spring, but it may be other materials such as rubber or a torsion spring.

[0089] In the embodiments described above, the robot control unit 30 and the tool control unit 31 were configured separately. However, it is sufficient that the functions of the robot control unit 30 and the tool control unit 31 can be realized. For example, the tool control unit may be incorporated into the robot control unit. Alternatively, it may be configured with one or more CPUs.

[0090] In embodiments 2 and 3 described above, the opening 16 was provided with a sliding door or a hinged door 20, but the door is not limited to a sliding door or a hinged door; it may be a folding door, or two or more sliding doors, hinged doors, or double sliding doors. The mechanism for opening and closing the door may also be a mechanism other than a rack and pinion or link mechanism, such as a worm gear, or any other mechanism. Alternatively, the door may be opened and closed by an independent power and control that is not linked to the processing tool 13. In this case, it is preferable to place an actuator separately from the cylinder 12 and open and close the door in synchronization with the movement of the cylinder 12.

[0091] In the embodiments described above, the connecting plate 18 had a stepped cross-section, but its shape and arrangement are not limited as long as the cylinder 12 allows the processing tool 13 to be exposed from the housing 11 and the elastic member 14 allows the processing tool 13 to be retracted into the housing 11. For example, a connecting plate 18 having processing tool mounting portions 18B fixed to the +Y direction end face and -X direction end face of the processing tool 13, as shown in Figure 13, may be used, or a flat connecting plate may be used. Alternatively, for example, as shown in Figure 14, the cylinder 12 and elastic member 14 may be directly connected to the processing tool 13 without using a connecting plate, allowing the processing tool 13 to move forward and backward, and the arrangement of each component within the housing 11 may be changed in various ways.

[0092] Furthermore, in the above embodiment 4, the human detection sensors 51, 52, and 53 had detection areas R1, R2, and R3 as their detection ranges, respectively. However, a single human detection sensor may have multiple detection areas as its detection range and identify which detection area detected the worker 200.

[0093] In the above embodiment 4, in step S203, the operator 200 entered the work area where the robot arm 6 was located and waited until the operator 200 left the work area. Alternatively, if the answer to step S203 is Yes, the process may return to step S202 to move the robot arm 6 to another work area and process another workpiece.

[0094] In the above embodiment 4, step S209 determined whether or not the worker 200 entered a single detection area including the work area where the robot arm 6 was working. However, it is also possible to determine whether or not the worker 200 entered all detection areas, including other detection areas. This makes it possible to select a workpiece 100 located in a detection area where no person has entered in a single step, even if the worker 200 has entered multiple areas, or if the worker 200 and another person have entered different areas, thereby reducing downtime.

[0095] In the above embodiment 4, the robot arm 6 was moved after the processing tool 13 was stored in the storage section 11 in step S211, returning to step S202. However, the robot arm 6 may be moved while the processing tool 13 is stored in the storage section 11.

[0096] This disclosure allows for various embodiments and modifications without departing from the broad spirit and scope of this disclosure. Furthermore, the embodiments described above are for illustrative purposes only and do not limit the scope of this disclosure. In other words, the scope of this disclosure is indicated by the claims, not by the embodiments. Various modifications made within the scope of the claims and the equivalent significance of the disclosure are considered to be within the scope of this disclosure.

[0097] This application is based on Japanese Patent Application No. 2023-017015, filed on 7 February 2023. The entire specification, claims, and drawings of Japanese Patent Application No. 2023-017015 are incorporated herein by reference.

[0098] (Note) This disclosure can be implemented in the following forms: (Note 1) Processing equipment for processing workpieces, A housing section capable of accommodating the aforementioned processing equipment, A sensor that detects pre-defined objects within a pre-defined detection area, A control unit that, in response to the sensor detecting a pre-set object in the detection area, houses the processing device in the housing section, A robotic system equipped with the following features. (Note 2) Multiple detection areas are set. When the object to be detected enters a detection area which includes the location where the robot is processing the workpiece with the processing device, the control unit moves the processing device to the housing unit and moves the robot to a detection area other than the detection area which includes the location where the robot is processing the workpiece with the processing device, and has the robot process the workpiece. The robot system described in Appendix 1. (Note 3) After housing the processing device in the storage unit, the robot is moved to a detection area other than the detection area that includes the location where the processing device is processing the workpiece, and the robot is then allowed to process the workpiece. The robot system described in Appendix 2. (Note 4) The aforementioned storage unit includes an openable and closable door and a door drive unit for opening and closing the door. The control unit controls the door drive unit to open the door when the processing equipment is exposed from the storage compartment, and close the door after the processing equipment has been stored in the storage compartment. A robotic system described in any one of the appendices 1 to 3. (Note 5) The processing device is equipped with a moving part, The control unit controls the moving part to house the processing device in the housing and to expose the processing device from the housing. A robot system described in any one of the appendices 1 to 4. (Note 6) The aforementioned storage compartment is equipped with a door that can be opened and closed. The door opens in accordance with the action of exposing the processing instrument from the housing, and closes in accordance with the action of housing the processing instrument in the housing. The robot system described in Appendix 5. (Note 7) The opening and closing of the aforementioned door is performed via a rack and pinion or link mechanism that is linked to the operation of the processing device. The robot system described in Appendix 6. (Note 8) The control unit moves the housing to house the processing device and expose the processing device. A robotic system described in any one of the appendices 1 through 7. (Note 9) The aforementioned sensor detects the presence or absence of the object to be detected in the pre-set work area of ​​the robot system. A robotic system described in any one of the appendices 1 through 8. (Note 10) While the robot is processing the workpiece with the processing device, it detects when an object to be detected enters a pre-set detection area. In response to detection, the processing device is housed in the housing. A method for controlling a robot system. (Note 11) On the computer, The action of a robot processing a workpiece using a processing tool. An operation in which a sensor detects when an object to be detected enters a pre-set detection area during work processing. An operation to control the processing device to be housed in the housing in response to detection. A computer program that executes an action. [Explanation of Symbols]

[0099] 1 Robot system, 2 Robot, 3 Controller, 5, 51, 52, 53 Human detection sensors, 6 Robot arm, 7 Workbench, 8 Solenoid valve, 9 Flange, 10 Robot tool, 11 Housing, 12 Cylinder, 13 Machining tool, 14 Elastic member, 15 Main body, 16 Opening, 17 Small diameter section, 18 Connecting plate, 18A Advance / reverse mechanism connection section, 18B Machining tool mounting section, 18C Rack gear mounting section, 18D Cam follower mounting section, 18E Bending section, 19 Link mechanism, 20, 43 Door, 21, 22 Rack gear, 23, 24 Gear, 25, 44 Hinge, 26 Cam follower, 27 Cam, 27A Hollow section, 28, 29 Link, 30 Robot control section, 31 Tool control section, 32A, 32B Memory section, 33 Input I / F, 34 Output I / F, 35 Sensor signal line, 40 Monitoring sensor, 41 Tip, 42 Drive unit, 100, 101, 102, 103 Workpiece, 200 Operator, R1, R2, R3 Detection area, R4 Exclusion area.

Claims

1. Processing equipment for processing workpieces, A housing section capable of accommodating the aforementioned processing equipment, A sensor that detects pre-defined objects within a pre-defined detection area, A control unit that, in response to the sensor detecting a pre-set object in the detection area, houses the processing device in the housing section, Equipped with, The aforementioned storage compartment is equipped with a door that can be opened and closed. The door opens in accordance with the action of exposing the processing instrument from the housing, and closes in accordance with the action of housing the processing instrument in the housing. Robot system.

2. Processing equipment for processing workpieces, A housing section capable of accommodating the aforementioned processing equipment, A sensor that detects pre-defined objects within a pre-defined detection area, A control unit that, in response to the sensor detecting a pre-set object in the detection area, houses the processing device in the housing section, Equipped with, Multiple detection areas are set. When the object to be detected enters a detection area which includes the location where the robot is processing the workpiece with the processing device, the control unit moves the processing device to the housing unit and moves the robot to a detection area other than the detection area which includes the location where the robot is processing the workpiece with the processing device, and has the robot process the workpiece. Robot system.

3. After housing the processing device in the storage unit, the robot is moved to a detection area other than the detection area that includes the location where the processing device is processing the workpiece, and the robot is then allowed to process the workpiece. The robot system according to claim 2.

4. Processing equipment for processing workpieces, A housing section capable of accommodating the aforementioned processing equipment, A sensor that detects pre-defined objects within a pre-defined detection area, A control unit that, in response to the sensor detecting a pre-set object in the detection area, houses the processing device in the housing section, Equipped with, The aforementioned storage unit includes an openable and closable door and a door drive unit for opening and closing the door. The control unit controls the door drive unit to open the door when the processing equipment is exposed from the storage compartment, and close the door after the processing equipment has been stored in the storage compartment. Robot system.

5. Processing equipment for processing workpieces, A housing section capable of accommodating the aforementioned processing equipment, A sensor that detects pre-defined objects within a pre-defined detection area, A control unit that, in response to the sensor detecting a pre-set object in the detection area, houses the processing device in the housing section, A moving unit for moving the processing device, Equipped with, The control unit controls the moving part to house the processing device in the housing and to expose the processing device from the housing. The aforementioned storage compartment is equipped with a door that can be opened and closed. The door opens in accordance with the action of exposing the processing instrument from the housing, and closes in accordance with the action of housing the processing instrument in the housing. Robot system.

6. The opening and closing of the aforementioned door is performed via a rack and pinion or link mechanism that is linked to the operation of the processing device. The robot system according to claim 5.

7. The control unit moves the housing to house the processing device and expose the processing device. The robot system according to any one of claims 1 to 6.

8. The aforementioned sensor detects the presence or absence of the object to be detected in the pre-set work area of ​​the robot system. The robot system according to any one of claims 1 to 6.

9. Processing equipment for processing workpieces, A housing section capable of accommodating the aforementioned processing equipment, A sensor that detects pre-defined objects within a pre-defined detection area, A control unit that, in response to the sensor detecting a pre-set object in the detection area, houses the processing device in the housing section, Equipped with, Multiple detection areas are set. When the object to be detected enters a detection area which includes the location where the robot is processing the workpiece with the processing device, the control unit moves the processing device to the housing unit and moves the robot to a detection area other than the detection area which includes the location where the robot is processing the workpiece with the processing device. Robot system.

10. While the robot is processing the workpiece with the processing device, it detects when an object to be detected enters a pre-set detection area. In response to detection, the processing device is housed in a housing capable of accommodating the processing device. The aforementioned storage compartment is equipped with a door that can be opened and closed. The door opens in accordance with the action of exposing the processing instrument from the housing, and closes in accordance with the action of housing the processing instrument in the housing. A method for controlling a robot system.

11. On the computer, The action of a robot processing a workpiece using a processing tool. An operation in which a sensor detects when an object to be detected enters a pre-set detection area during work processing. An operation to control the processing device in response to detection, to house the processing device in a housing capable of housing the processing device. Make it run, The aforementioned storage compartment is equipped with a door that can be opened and closed. The door opens in accordance with the action of exposing the processing instrument from the housing, and closes in accordance with the action of housing the processing instrument in the housing. Computer program.

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