Design assisting device and design assisting method

Abstract

This design assisting device for assisting safety design of a work system including a robot comprises: a model display processing unit that displays, on a predetermined display screen, a three-dimensional model in which the robot and surrounding objects are placed in a virtual space; a sensor display processing unit that displays a safety sensor in the three-dimensional model such that the safety sensor is placed in a position and orientation based on a placement instruction provided by a designer, the safety sensor monitoring the surroundings of the robot; and an area display processing unit that displays, in the three-dimensional model, a detection area of the safety sensor placed in the three-dimensional model.

Description

Design support device and design support method

[0001] This specification discloses a design support apparatus and a design support method.

[0002] Conventionally, there have been proposals for generating a three-dimensional model in which a robot and peripheral elements (placement objects) are arranged in a virtual space, and verifying the robot's operation, safety, etc. For example, Patent Literature 1 describes including tools that exist in the real environment as peripheral elements in the three-dimensional model, and checking whether the robot and the tools interfere with each other.

[0003] Japanese Patent Application Laid-Open No. 2022-137797

[0004] As described in the above-mentioned Patent Document 1, verifying the safety of robots is considered an important issue. Furthermore, in recent years, the introduction of collaborative robots that work in the same space as workers has been progressing, so there is a need to improve safety not only for peripheral elements but also for surrounding workers. However, this can require a large amount of man-hours on the part of designers, placing a heavy burden on them.

[0005] A primary object of the present disclosure is to improve the safety of workers around robots while reducing the burden on designers.

[0006] The present disclosure has adopted the following means to achieve the above-mentioned main object.

[0007] The design support device disclosed herein is a design support device that supports the safety design of a work system including a robot, and comprises: a model display processing unit that displays a three-dimensional model in which the robot and surrounding objects are arranged in a virtual space on a predetermined display screen; a sensor display processing unit that displays, within the three-dimensional model, safety sensors that monitor the periphery of the robot so that they are arranged in positions and orientations based on arrangement instructions from a designer; and an area display processing unit that displays, within the three-dimensional model, the detection areas of the safety sensors arranged within the three-dimensional model.

[0008] In the design support device disclosed herein, safety sensors that monitor the robot's periphery are displayed in a three-dimensional model in which a robot and surrounding objects are arranged in a virtual space, with the sensors positioned and oriented based on the designer's placement instructions. The safety sensor detection areas are also displayed within the three-dimensional model. This allows the designer to easily optimize the safety sensor detection areas and placement locations, enabling the safety sensors to be appropriately placed around the robot. This reduces the burden on the designer and improves the safety of workers around the robot.

[0009] 1 is a schematic diagram of a safety sensor 10 and a PC 20. A schematic diagram of a work system 40 including a safety sensor 10 and a robot 50. A flowchart showing an example of the first half of the safety design support processing. A flowchart showing an example of the second half of the safety design support processing. An explanatory diagram showing an example of a safety design support screen 70. A flowchart showing an example of a hazard display processing. An explanatory diagram showing an example of a movable area X. An explanatory diagram showing an example of an intrusion area Y. An explanatory diagram showing an example of an overlap area Z. An explanatory diagram showing an example of a hazard D. An explanatory diagram showing an example of how the safety sensor 10 is positioned. An explanatory diagram showing an example of a detection area A of the safety sensor 10. An explanatory diagram showing an example of how the range of the detection area A has been changed. An explanatory diagram showing an example of how the movable area X and the detection area A are displayed.

[0010] An embodiment of the present disclosure will be described with reference to the drawings. Fig. 1 is a schematic configuration diagram of a safety sensor 10 and a PC 20. Fig. 2 is a schematic configuration diagram of a work system 40 including the safety sensor 10 and a robot 50. In this embodiment, the left-right direction, the front-rear direction, and the up-down direction are defined as shown in Fig. 2.

[0011] The safety sensor 10 includes a control unit 11 having a CPU, ROM, RAM, etc., a sensor unit 12 that detects surrounding objects, and a communication unit 13 that communicates with external devices such as the PC 20 and the robot 50. The sensor unit 12 of the safety sensor 10 is, for example, a laser or millimeter-wave radar. The sensor unit 12 monitors the presence or absence of a worker M within a set detection area (monitoring area) A within a detectable area (maximum detection area) that is a substantially fan-shaped area when viewed from above and in which objects can be detected.

[0012] The PC 20 is a general-purpose computer that supports a designer, such as an administrator or worker M, of the work system 40 when performing various safety designs, including setting the detection area A of the safety sensor 10. The PC 20 includes a control unit 21 having a CPU, ROM, RAM, etc.; a storage unit 22, such as an HDD, that stores various application programs and various data; and a communication unit 23 that communicates with external devices connected via a network and with the safety sensor 10 connected via a communication line 18. The communication line 18 may be, for example, a USB cable. The PC 20 and the safety sensor 10 may also be connected wirelessly for communication. The PC 20 also includes an input unit 27, such as a keyboard or touchpad, through which a designer, such as an administrator or worker M, inputs various information, and a display screen 28, such as a liquid crystal display. The PC 20 of this embodiment is capable of constructing a three-dimensional model MD of the work system 40 in a virtual space using a digital twin and performing various simulations and safety designs using the three-dimensional model MD.

[0013] The work system 40 includes, for example, a robot 50, a robot platform 41 on which the robot 50 is mounted, a conveyor device 43, a mounting table 45, and one or more safety sensors 10. The conveyor device 43 and the mounting table 45 are disposed, for example, on opposite sides of the robot 50 in the left-right direction. The conveyor device 43 includes a roller conveyor 43a and an end table 43b. The roller conveyor 43a has multiple rollers and conveys the item P in the left-right direction by transmitting power from a motor (not shown) to each roller to rotate it. The end tables 43b are provided at both left-right ends of the conveyor device 43 (only one end is shown in FIG. 2) and are used as temporary storage locations for the item P before or after transport. The mounting table 45 has an upper surface divided into multiple mounting areas 45a, and the worker M or the robot 50 places the item P in each mounting area 45a. Pillars 47 and other components are also provided within the work system 40. The robot stand 41, the conveyor device 43, the mounting table 45, and the pillars 47 are also referred to as arranged objects (fixed objects).

[0014] The robot 50 includes a vertical articulated robot arm 52 in which multiple links are rotatably connected via joints, an end effector 54 as a work tool detachable from the distal link of the robot arm 52, a control unit, an imaging unit (not shown), and the like. The end effector 54 may be an electromagnetic chuck, a mechanical chuck, a suction nozzle, or the like, and is selected based on the shape and material of the article P. In the example shown in FIG. 2 , a mechanical chuck having a pair of openable and closable chuck jaws is attached. The robot 50 grips a knob (protrusion) Pa formed on the top surface of the article P with the mechanical chuck and transfers the article P between the conveyor device 43 and the mounting table 45. The control unit of the robot 50 receives detection signals from an encoder that detects the rotation angle of each joint of the robot arm 52, detection signals from the safety sensor 10, and images captured by the imaging unit, and controls the operation of the robot arm 52 and the end effector 54.

[0015] In the work system 40, a worker M may work around the robot 50. That is, the robot 50 of the work system 40 is used as a collaborative robot that works in the same work space as the worker M. In the work system 40, a plurality of safety sensors 10 are arranged to improve the safety of the worker M around the robot 50. Although three safety sensors 10 are shown in FIG. 2, for example, four safety sensors 10 are arranged on the robot stand 41 so as to monitor the entire circumference of the robot 50 in four directions (front, back, left, and right) around the center. The arrangement positions, orientations, and detection areas A of these safety sensors 10 are each set as part of the safety design of the work system 40. FIG. 3 is a flowchart showing an example of a safety design support process. This process is executed by the control unit 21 of the PC 20.

[0016] In the safety design support process, the control unit 21 generates a three-dimensional model MD including the robot 50 and its peripheral objects such as the robot stand 41, the conveyor device 43, the mounting table 45, and the pillars 47, and displays it on the safety design support screen 70 on the display screen 28 (S100). The control unit 21 acquires, for example, design information and three-dimensional CAD data including the sizes of the robot 50 and its peripheral objects, placement information regarding the placement position, and operation information including the operating range and operating speed of each joint of the robot arm 52 of the robot 50, and the type and operation of the end effector 53, and generates and displays the three-dimensional model MD in virtual space.

[0017] FIG. 5 is an explanatory diagram showing an example of a safety design support screen 70. The safety design support screen 70 displays a model display field 71 and various buttons. The model display field 71 displays a three-dimensional model MD including the robot 50 of the work system 40 and surrounding objects. The various buttons displayed include a sensor placement button 72, a movement / entry area display button 73, a parameter setting button 74, a hazard source display button 75, a save button 76, an output button 77, and an end button 78. An instruction pointer 79 that the designer can operate via the input unit 27 is also displayed. The sensor placement button 72 is a button for instructing the placement of the safety sensor 10. The movement / entry area display button 73 is a button for switching the display of various areas, such as the movement area X of the robot 50, the entry area Y of the worker M, and the overlap area Z between the movement area X and the entry area Y. Each time the button is operated, the button sequentially switches between displaying and hiding one of the three areas. The parameter setting button 74 is a button for setting parameters that determine the detection area of ​​the safety sensor 10. Details of the parameters will be described later. The hazard display button 75 is a button for displaying hazards D within the overlap area Z, and each time it is operated, it switches between displaying and hiding one or more hazards D. The save button 76 is a button for saving the state currently displayed in the model display field 71. The output button 77 is a button for outputting setting information such as set parameters to the safety sensor 10. The end button 78 is a button for ending the safety design. The instruction pointer 79 is used to operate various buttons, set various parameters, move the safety sensor 10 within the three-dimensional model MD, and operate the robot arm 52 of the robot 50.

[0018] Next, the control unit 21 determines whether the hazard display button 75 on the safety design support screen 70 has been operated (S105), and if it determines that the hazard display button 75 has been operated, executes hazard display processing (S110).

[0019] 6 is a flowchart showing an example of the hazard display process. In the hazard display process, the control unit 21 determines whether the display of the hazard D has been turned on (S200). If it is determined that the display of the hazard D has not been turned on, the process proceeds to S245. Note that the control unit 21 determines that the display of the hazard D has been turned on if the hazard display button 75 is operated when the hazard D is not displayed in the three-dimensional model MD on the safety design support screen 70. Also, the control unit 21 determines that the display of the hazard D has been turned off if the hazard display button 75 is operated when the hazard D is displayed in the three-dimensional model MD on the safety design support screen 70. When the control unit 21 determines that the display of the hazard D has been turned on for the first time in the displayed three-dimensional model MD, it sets the movement area X of the robot 50 and the entry area Y of the worker M (S205). If the hazard D for the three-dimensional model MD being displayed has already been set, the control unit 21 skips steps S205 to S235 and proceeds to step S240, where it displays the hazard D as described below.

[0020] FIG. 7 is an explanatory diagram showing an example of the movable area X. The movable area X is set, for example, as a substantially hemispherical spatial area based on the movement trajectory of the end effector 54 attached to the robot 50. In setting the movable area X, the control unit 21 calculates a movement trajectory along which the end effector 54 of the robot 50 can move based on the position information and operation information of the robot 50, and sets the substantially hemispherical spatial area formed by the movement trajectory as the movable area X. FIG. 8 is an explanatory diagram showing an example of the entry area Y. The colored area in FIG. 8 indicates the bottom surface of the entry area Y. The entry area Y includes not only an area within which the worker M can move, such as the movement path of the worker M, but also an area on the robot platform 41 into which parts of the worker M's body, such as their hands and arms, can enter. For this reason, the control unit 21 sets the entry area Y as a spatial area whose height is a height from the bottom surface that the worker M can reach, as shown by the dotted line in FIG. 8 . In the example of FIG. 8, the area above the end table 43b of the conveyor device 43 and the area above the placement area 45a of the placement table 45 are excluded from the entry area Y, but these areas may be included.

[0021] Next, the control unit 21 extracts interference points and gap points from an overlap area Z where the movable area X and the entry area Y overlap (S210). FIG. 9 is an explanatory diagram showing an example of the overlap area Z. The overlap area Z is set as the area where the movable area X and the entry area Y overlap. The hatched area in FIG. 9 indicates the bottom area of ​​the overlap area Z. The overlap area Z includes the area around the robot 50 (robot platform 41), as well as the area on the robot platform 41, the area on the end table 43b of the conveyor device 43, and a portion of the placement area 45a of the placement table 45. The interference points are areas where a part of the body of the worker M may interfere with (contact with) the robot 50 (robot arm 52, end effector 54) during operation. The gap points are areas where a gap is formed where a part of the body of the worker M may enter, such as a joint of the robot arm 52 of the robot 50.

[0022] Next, the control unit 21 determines whether there is an interference area within the overlap region Z (S215). If it determines that there is no interference area, the process proceeds to S225. As described above, since the robot 50 is used as a collaborative robot, it is usually determined that there is an interference area in S215. If the control unit 21 determines that there is an interference area, it sets a risk level based on the shape, material, and operating speed of the robot 50 at the interference area (S220) and proceeds to S225. If there are multiple interference areas, the control unit 21 sets a risk level for each interference area. In S220, the risk level is set so that the sharper the shape, the harder the material, and the faster the operating speed. Therefore, for example, if a mechanical chuck is attached as the end effector 54, the risk level is set higher because the shape is sharper and the material is harder than a suction nozzle. The control unit 21 may set the risk level based on at least one of the shape, material, and operating speed of the robot 50 at the interference location.

[0023] Furthermore, the control unit 21 determines whether or not there is a gap within the overlap region Z (S225), and if it determines that there is no gap, the process proceeds to S235. If the control unit 21 determines that there is a gap, the control unit 21 sets a risk level based on the gap dimension of the robot 50 at the gap (S230), and proceeds to S235. In S230, if the gap dimension is large enough to prevent the worker M from getting their fingers or hands caught, the risk level is set to low, and if the gap dimension is small enough to cause the worker M to get their fingers or hands caught, the risk level is set to high. Furthermore, if the gap dimension changes as the robot 50 operates, the risk level is set based on whether or not the changing dimensional range includes a small gap dimension that could cause a finger or hand to get caught. Note that the risk level for the gap may also be set taking into account the shape and material of the robot 50 constituting the gap in the same manner as for the interference area.

[0024] The control unit 21 then determines whether there are any locations where the level of danger is equal to or greater than the reference value (S235), and if it determines that there are no locations where the level of danger is equal to or greater than the reference value, proceeds to S245. On the other hand, if the control unit 21 determines that there are any locations where the level of danger is equal to or greater than the reference value, it sets those locations as hazard D and displays them on the three-dimensional model MD (S240), and proceeds to S245. Next, the control unit 21 determines whether the display of hazard D has been turned off (S245), and if it determines that it has not been turned off, it terminates this processing. If it determines that the display of hazard D has been turned off, the control unit 21 erases the display of hazard D that was being displayed on the three-dimensional model MD (S250), and terminates this processing.

[0025] FIG. 10 is an explanatory diagram showing an example of a hazard D, in which two hazards D1 and D2 are displayed. The hazard D1 is an interference point at the tip of the end effector 54 of the robot 50. The hazard D2 is a gap at a joint of the robot arm 52 of the robot 50. Note that gaps at other joints are not set as hazards D because, for example, the gap dimensions are too large to pinch the operator M's hand even when the robot arm 52 is operated, or the gap dimensions are too small for the operator M's hand to fit in. In this way, the hazards D are displayed on the safety design support screen 70, allowing the designer to easily understand the hazards D. Note that clicking on the hazards D1 and D2 surrounded by dotted lines may display the level of hazard or the factors that increased the level of hazard, such as the material and gap dimensions.

[0026] In the safety design support process of FIG. 3 , the control unit 21 executes the hazard display process in S110. If the control unit 21 determines in S105 that the hazard display button 75 has not been operated, it determines whether an instruction to place the safety sensor 10 has been issued based on whether the sensor placement button 72 has been operated (S115). If the control unit 21 determines that an instruction to place the safety sensor 10 has not been issued, it proceeds to S125. If the control unit 21 determines that an instruction to place the safety sensor 10 has been issued, it displays the safety sensor 10 in the three-dimensional model MD so that the safety sensor 10 is positioned and oriented in accordance with the placement instruction (S120). The control unit 21 also determines whether an instruction to display the detection area A of the placed safety sensor 10 has been issued (S125), and if it determines that an instruction to display the detection area A has been issued, it displays the detection area A in the three-dimensional model MD (S130). On the other hand, if the control unit 21 determines that an instruction to display the detection area A has not been issued, it hides the detection area A (S135) and proceeds to S150.

[0027] FIG. 11 is an explanatory diagram showing an example of how a safety sensor 10 is arranged in a three-dimensional model MD. For example, the designer can drag and drop the safety sensor 10 in the model display field 71 using the instruction pointer 79 on the safety design support screen 70 to move and arrange the safety sensor 10 to a desired position in the model display field 71. When a safety sensor 10 is selected in the model display field 71 on the safety design support screen 70, a setting dialog 72a is also displayed for setting the position, angle, and other parameters of the safety sensor 10. The setting dialog 72a allows the user to set the position coordinates of the safety sensor 10 in the X direction (horizontal direction) and Y direction (vertical direction) and the orientation (angle) in the horizontal and vertical directions. That is, the arrangement position of the safety sensor 10 can be set by operating the instruction pointer 79 or by specifying the position coordinates. The setting dialog 72a also allows the user to turn on or off the display of the detection area A of the selected safety sensor 10 and to add a new safety sensor 10. For example, when a blank area on the safety design support screen 70 is clicked, the setting dialog 72a disappears.

[0028] FIG. 12 is an explanatory diagram showing an example of the detection area A of the safety sensor 10. In this embodiment, the detection area A includes a first detection area A1 closer to the safety sensor 10 and a second detection area A2 farther from the safety sensor 10. The first detection area A1 is, for example, an area up to a first distance (predetermined distance) from the safety sensor 10, and is an area in which the operation of the robot 50 is stopped when a worker M or the like is detected. The second detection area A2 is, for example, an area from the first distance to a second distance from the safety sensor 10, and is an area in which the operation speed of the robot 50 is slowed down when a worker M or the like is detected. The control unit 21 displays each area on the safety design support screen 70 in different display modes, such as different display colors, so that the designer can distinguish between them. Note that the number of detection areas A is not limited to two, and may be three or more. Although not shown, the designer may be able to set the boundaries of each area, such as the first distance that defines the boundary between the first detection area A1 and the second detection area A2.

[0029] When the detection area A is displayed in this manner, the control unit 21 determines whether a parameter setting instruction has been issued based on whether the parameter setting button 74 has been operated (S140), and if it determines that a parameter setting instruction has not been issued, the process proceeds to S150. If it determines that a parameter setting instruction has been issued, the control unit 21 changes the detection area A to a detection range corresponding to the set parameter (S145), and then proceeds to S150.

[0030] FIG. 13 is an explanatory diagram showing an example of how the range of the detection area A has been changed. As shown in the figure, operating the parameter setting button 74 displays a setting dialog 74a for setting the range of the detection area A. In the setting dialog 74a, parameters such as "distance," "width," "horizontal angle," and "vertical angle" can be set by moving sliders using the instruction pointer 79. The "distance" is a detection distance corresponding to the radius of the approximately sector-shaped detection area A centered on the safety sensor 10, and a lower and upper limit can be set. For example, a designer can set the lower limit to a value other than 0 to define the area from the safety sensor 10 to the lower limit as a non-detection area. The "width" is the horizontal (left-right) detection width defined by a pair of parallel lines centered on the safety sensor 10. The area inside this detection width is the detection area, and the area outside the detection width is the non-detection area. The "horizontal angle" determines the horizontal central angle of the detection area A, i.e., the horizontal spread angle. The "vertical angle" determines the central angle in the vertical direction of the detection area A, i.e., the spread angle in the vertical direction. In Fig. 13, for example, the "horizontal angle" in the setting dialog 74a is changed to be narrower, and the displayed detection area A has a narrower central angle in the horizontal direction than the detection area A in Fig. 12. Note that, for example, if a blank area on the safety design support screen 70 is clicked, the setting dialog 74a will not be displayed.

[0031] Next, the control unit 21 determines whether or not a command to display the movable area X or the entry area Y has been issued based on whether the movable / entry area display button 73 has been operated (S150), and if it determines that a command has not been issued, proceeds to S160. If the control unit 21 determines that a command to display has been issued, it displays either the movable area X of the robot 50, the entry area Y of the worker M, or the overlap area Z of the movable area X and the entry area Y (S155). As described above, each time the movable / entry area display button 73 is operated, the display of one of the three areas is switched sequentially between displaying one of the three areas and not displaying any of the areas. Furthermore, the three areas that are set in the same way as in S205 of the risk level display processing are displayed.

[0032] 14 is an explanatory diagram showing an example of how the movable area X and the detection area A are displayed. For example, when the detection area A is displayed in S130, the movable area X is displayed in S155, so that both the movable area X and the detection area A are displayed together. This allows the designer to easily check whether the detection area A is appropriate for the movable area X. Furthermore, with the movable area X and the detection area A displayed together, the designer can optimize the range of the detection area A to match the range of the movable area X by changing the settings of the "distance," "width," "horizontal angle," and "vertical angle" of the detection area A in the setting dialog 74a.

[0033] Next, the control unit 21 determines whether an instruction to output to the safety sensor 10 has been issued based on whether the output button 77 has been operated (S160), and if it determines that an instruction has not been issued, the process proceeds to S170. If it determines that an instruction to output has been issued, the control unit 21 outputs the setting information of the detection area A being displayed, i.e., the setting values ​​of each parameter, to the connected safety sensor 10 (S165), and then proceeds to S170.

[0034] The control unit 21 then determines whether an end command has been issued based on whether the end button 78 has been operated (S170), and if it determines that an end command has not been issued, the process returns to S105. If the control unit 21 determines that an end command has been issued, the process ends. Although not shown in FIGS. 3 and 4 , if the control unit 21 determines that a save command has been issued based on the operation of the save button 76, the control unit 21 saves the state displayed in the model display field 71 in the storage unit 22. The designer can read out the saved content via an operation on a read screen (not shown) and redesign on the safety design support screen 70.

[0035] Here, the correspondence between the components of this embodiment and the components of the present disclosure will be clarified. The control unit 21 that executes S100 of the safety design support processing of this embodiment corresponds to the model display processing unit of the present disclosure, the control unit 21 that executes S120 of the same processing corresponds to the sensor display processing unit, and the control unit 21 that executes S130 of the same processing corresponds to the area display processing unit. The control unit 21 that executes S165 of the same processing corresponds to the output unit. The control unit 21 that executes S205 of the hazard display processing and S155 of the safety design support processing corresponds to the area setting unit, and the control unit 21 that executes S210 to S240 of the hazard display processing corresponds to the hazard display processing unit. Note that in this embodiment, an example of the design support method of the present disclosure is also clarified by explaining the operation of the PC 20.

[0036] In the PC 20 (design support device) of the embodiment described above, the safety sensor 10 is displayed in a three-dimensional model MD in which the robot 50 and surrounding objects (41, 43, 45, 47) are arranged in a virtual space, with the safety sensor 10 positioned and oriented based on the designer's placement instructions. The detection area A of the safety sensor 10 is also displayed in the three-dimensional model MD. This allows the designer to easily check the detection area A of the safety sensor 10 while appropriately changing the placement position and orientation of the safety sensor 10. That is, the designer can easily optimize the detection area A and placement position of the safety sensor 10. Furthermore, the safety sensor 10 can be appropriately placed around the robot 50 based on the position and orientation of the safety sensor 10 optimized by the PC 20. This significantly reduces the designer's burden compared to adjusting the detection area A while appropriately changing the placement position and orientation of the safety sensor 10 on-site (at the installation site of the work system 40). Therefore, the safety of the worker M around the robot 50 can be improved while reducing the designer's burden.

[0037] Furthermore, the PC 20 displays the detection area A so that it becomes a detection range based on the setting information including at least one of the layout instructions from the designer and the detection distance ("distance"), detection angle ("horizontal angle", "vertical angle") and non-detection area ("width") set in the safety sensor 10. This allows the designer to easily set an appropriate range for the detection area A, thereby further improving the safety of the worker M.

[0038] Furthermore, the detection area A has a plurality of divided areas (first detection area A1, second detection area A2) so that the robot 50 responds differently when the safety sensor 10 detects an object (including the worker M). The PC 20 displays the detection area A so that the plurality of areas can be distinguished. This allows the designer to easily check the plurality of areas and set the detection area A more appropriately, thereby further improving the safety of the worker M.

[0039] Furthermore, the PC 20 can display the movable area X of the robot 50 based on the position information and operation information of the robot 50, together with the detection area A of the safety sensor 10, in the three-dimensional model MD. This allows the designer to easily check whether the detection area A is appropriate for the movable area X.

[0040] The PC 20 is also configured to be able to communicate with the safety sensor 10 via a communication line 18 (wired), and based on an output instruction from the designer, outputs setting information for the detection area A displayed on the safety design support screen 70 (model display field 71) to the connected safety sensor 10. Therefore, the designer only needs to check the displayed detection area A and give an output instruction, further reducing the burden on the designer.

[0041] Furthermore, the PC 20 sets, within the three-dimensional model MD, a movable area X of the robot 50 and an entry area Y into which at least part of the worker's body can enter. The PC 20 then determines whether or not there is a hazard D within an overlapping area Z between the movable area X and the entry area Y, and displays the hazard D within the three-dimensional model MD if it determines that there is a hazard D. This allows the designer to easily grasp the hazard D, and therefore allows for more appropriate placement of the safety sensor 10 and setting of the detection area A.

[0042] Furthermore, the PC 20 extracts from the overlapping area Z any location where part of the worker M's body may come into contact with the robot 50 or may be pinched between the robot 50, and determines whether or not that location is a hazard D based on at least one of the shape, material, dimensions, and operating speed of that location. This makes it possible to extract hazard D with simple processing and have the designer confirm it.

[0043] It goes without saying that the present disclosure is not limited to the above-described embodiments, and can be embodied in various forms as long as they fall within the technical scope of the present disclosure.

[0044] In the embodiment, the hazard D is displayed within the three-dimensional model MD, but this is not limited to this, and the hazard D does not have to be displayed within the three-dimensional model MD, and S105 and S110 of the safety design support processing may be omitted.

[0045] In the embodiment, the PC 20 outputs the setting information of the detection area A to the safety sensor 10, but this is not limited to this, and the setting information of the detection area A does not have to be output to the safety sensor 10, and S160 and S165 of the safety design support processing may be omitted.

[0046] In the embodiment, the PC 20 displays either the movable area X of the robot 50, the entry area Y of the worker M, or the overlap area Z together with the detection area A in the three-dimensional model MD, but this is not limited to this. The PC 20 only needs to be able to display at least the movable area X of the robot 50 together with the detection area A in the three-dimensional model MD. Alternatively, the PC 20 does not need to display the movable area X of the robot 50, etc. together with the detection area A in the three-dimensional model MD, and steps S150 and S155 of the safety design support processing may be omitted.

[0047] In the embodiment, the PC 20 displays the detection area A so that multiple areas (first detection area A1, second detection area A2) can be distinguished, but this is not limited thereto, and the PC 20 may be able to switch between a display in which the multiple areas can be distinguished and a display in which the multiple areas cannot be distinguished. Furthermore, the PC 20 does not have to display multiple areas so that the multiple areas can be distinguished. Alternatively, the safety sensor 10 is not limited to having multiple areas, and may not have multiple areas.

[0048] In the embodiment, the PC 20 displays the detection area A so as to be a detection range based on the placement instructions from the designer and setting information including the detection distance, detection angle, and non-detection area set for the safety sensor 10. However, this is not limited to this. For example, the PC 20 may display the detection area so as to be a detection range based on the placement instructions from the designer and the default detection distance and detection angle of the safety sensor 10. That is, the PC 20 may display the safety sensor 10 in the three-dimensional model MD at a position and orientation based on at least the placement instructions, and may display the default detectable area of ​​the safety sensor 10 in the three-dimensional model MD. Furthermore, although the PC 20 is exemplified as the design support device, a smartphone, a tablet terminal, or the like may also be used.

[0049] In the embodiment, the hazard display processing is performed in the safety design support processing for displaying and setting the detection area A of the safety sensor 10, but the present invention is not limited to this, and the hazard display processing may be performed independently of the display and setting of the detection area A of the safety sensor 10. That is, the design support device of the present disclosure may be configured as follows.

[0050] That is, a second design support device of the present disclosure is a design support device that supports the safety design of a work system that includes a robot, and comprises: a model display processing unit that displays a three-dimensional model in which the robot and surrounding objects are arranged in a virtual space on a predetermined display screen; an area setting unit that sets, within the three-dimensional model, a movement area of ​​the robot and an entry area into which at least a part of the body of a worker can enter; and a hazard display processing unit that determines the presence or absence of a hazard within an overlapping area between the movement area and the entry area, and displays the hazard within the three-dimensional model if it is determined that the hazard exists.

[0051] In the second design support device of the present disclosure, a movement area X of the robot 50 and an entry area Y into which at least a part of the body of the worker M can enter are set within a three-dimensional model MD in which the robot 50 and surrounding objects (41, 43, 45, 47) are arranged in a virtual space. In addition, the presence or absence of a hazard D within an overlapping area Z of the movement area X and the entry area Y is determined, and if it is determined that a hazard D exists, the hazard D is displayed within the three-dimensional model MD. This allows the designer to easily check for the hazard D in the work system 40 and take appropriate action. Therefore, the safety of the worker M around the robot 50 can be improved while reducing the burden on the designer.

[0052] This specification also discloses the technical idea of ​​changing "the design support device according to claim 1 or 2" in claim 4 at the time of filing to "the design support device according to any one of claims 1 to 3", the technical idea of ​​changing "the design support device according to claim 1 or 2" in claim 5 at the time of filing to "the design support device according to any one of claims 1 to 4", and the technical idea of ​​changing "the design support device according to claim 1" in claim 6 at the time of filing to "the design support device according to any one of claims 1 to 5".

[0053] The present disclosure is applicable to the safety design of work systems including robots.

[0054] 10 Safety sensor, 11, 21 Control unit, 12 Sensor unit, 13, 23 Communication unit, 18 Communication line, 20 PC (design support device), 22 Memory unit, 27 Input unit, 28 Display screen (display unit), 40 Work system, 41 Robot stand, 43 Conveyor device, 43a Roller conveyor, 43b End table, 45 Placement table, 45a Placement area, 47 Pillar, 50 Robot, 52 Robot arm, 54 End effector, 70 Safety design support screen, 71 Model display field, 72 Sensor placement button, 73 Movable / entry area display button, 74 Parameter setting button, 75 Hazard display button, 76 Save button, 77 Output button, 78 End button, 79 Instruction pointer, A Detection area, A1 First detection area, A2 Second detection area, D, D1, D2 Hazard, M Operator, P Item, Pa knob part.

Claims

1. A design support device for supporting the safety design of a work system including a robot, comprising: a model display processing unit that displays a three-dimensional model in which the robot and surrounding objects are arranged on a virtual space on a predetermined display screen; a sensor display processing unit that displays in the three-dimensional model a safety sensor that monitors the periphery of the robot so as to be arranged at a position and in a direction based on an arrangement instruction by a designer; and a region display processing unit that displays a detection region of the safety sensor arranged in the three-dimensional model in the three-dimensional model.

2. The design support device according to claim 1, wherein the region display processing unit displays the detection region so as to be a detection range based on at least one of an arrangement instruction by a designer and setting information including at least one of a detection distance, a detection angle, and a non-detection region set for the safety sensor.

3. The design support device according to claim 1 or 2, wherein the detection region has a plurality of regions divided so that the response performed by the robot when an object is detected by the safety sensor is different, and the region display processing unit displays the detection region so that the plurality of regions can be discriminated.

4. The design support device according to claim 1 or 2, wherein the region display processing unit can display, in the three-dimensional model, a movable region of the robot based on the arrangement information and operation information of the robot together with the detection region of the safety sensor.

5. The design support device according to claim 1 or 2, further comprising: an output unit configured to be communicable with the safety sensor by wire or wirelessly, and outputting, based on an output instruction by a designer, the setting information of the detection region displayed by the region display processing unit to the connected safety sensor.

6. The design support device according to claim 1, further comprising: a region setting unit that sets, in the three-dimensional model, a movable region of the robot and at least an intrusion region into which a part of the body of an operator can intrude; and a hazard source display processing unit that determines the presence or absence of a hazard source in an overlapping region between the movable region and the intrusion region, and displays the hazard source in the three-dimensional model when it is determined that there is a hazard source.

7. A design support device for supporting the safety design of a work system including a robot, comprising: a model display processing unit that displays a three-dimensional model in which the robot and surrounding arrangements are arranged on a virtual space on a predetermined display screen; a region setting unit that sets, in the three-dimensional model, a movable region of the robot and an intrusion region into which at least a part of an operator's body can intrude; and a hazard source display processing unit that determines the presence or absence of a hazard source in an overlapping region between the movable region and the intrusion region, and displays the hazard source in the three-dimensional model when it is determined that there is a hazard source.

8. The design support device according to claim 6 or 7, wherein the hazard source display processing unit extracts, from the overlapping region, a location where a part of an operator's body can come into contact with the robot or be pinched by the robot, and determines whether the location is a hazard source based on at least one of the shape, material, dimensions, and operating speed of the location.

9. A design support method for supporting the safety design of a work system including a robot, comprising: (a) a step of displaying a three-dimensional model in which the robot and surrounding arrangements are arranged on a virtual space on a predetermined display screen; (b) a step of displaying, in the three-dimensional model, a safety sensor for monitoring the surroundings of the robot so as to be arranged at a position and in a direction based on an arrangement instruction by a designer; and (c) a step of displaying a detection region of the safety sensor arranged in the three-dimensional model in the three-dimensional model.

10. A design support method for supporting the safety design of a work system including a robot, comprising: (a) a step of displaying a three-dimensional model in which the robot and surrounding arrangements are arranged on a virtual space on a predetermined display screen; (b) a step of setting, in the three-dimensional model, a movable region of the robot and an intrusion region into which at least a part of an operator's body can intrude; and (c) a step of determining the presence or absence of a hazard source in an overlapping region between the movable region and the intrusion region, and displaying the hazard source in the three-dimensional model when it is determined that there is a hazard source.