Sensor system and robot system

Abstract

This sensor system comprises: a sensor unit capable of detecting an object in a detection area defined by the distance from a sensor origin, the angle in the horizontal direction, and the angle in the vertical direction; a reception unit capable of receiving, as setting conditions, a distance range from the sensor origin to the detection area, an angular range in the horizontal direction, and an angular range in the vertical direction; a setting unit that sets a detection range or a non-detection range on the basis of the setting conditions; and a detection unit that detects, in the detection area, an object included in the detection range or an object not included in the non-detection range.

Description

Sensor Systems and Robot Systems

[0001] Disclosed herein are sensor systems and robotic systems.

[0002] Conventionally, in a radar device capable of setting a line-of-sight area in which targets are detected and a non-line-of-sight area in which targets are not detected within a detection area, a device has been proposed that sets a fan-shaped line-of-sight area by setting the distance and vertical angle, and also sets an arc-shaped non-line-of-sight area (a shape obtained by removing a smaller fan-shaped line-of-sight area from the fan-shaped detection area) (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2017-44567

[0004] However, in the above-described radar device, since only the vertical angle can be set when setting the arc-shaped non-line-of-sight area, there is a risk that the horizontal width will be set too large.

[0005] A main object of the present disclosure is to enable the detection range or non-detection range within a detection area detectable by a sensor unit to be set just enough.

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

[0007] The sensor system of the present disclosure comprises a sensor unit capable of detecting an object within a detection area defined by a distance from a sensor origin, a horizontal angle, and a vertical angle; a receiving unit capable of receiving a distance range from the sensor origin for the detection area, a horizontal angle range, and a vertical angle range as setting conditions; a setting unit that sets a detection range or a non-detection range based on the setting conditions; and a detection unit that detects an object within the detection area that is included in the detection range or an object that is not included in the non-detection range.

[0008] The sensor system of the present disclosure accepts a distance range, a horizontal angle range, and a vertical distance range as setting conditions, and sets a detection range or non-detection range based on the setting conditions. By appropriately setting these ranges, it is possible to set the detection range or non-detection range just right.

[0009] The robot system of the present disclosure comprises a robot; a sensor unit capable of detecting an object within a detection area defined by a distance from a sensor origin, a horizontal angle, and a vertical angle; a reception unit capable of receiving a distance range from the sensor origin for the detection area, a horizontal angle range, and a vertical angle range as setting conditions; a setting unit that sets a detection range or a non-detection range based on the setting conditions; a detection unit that detects an object that is within the detection area and is included in the detection range or an object that is not included in the non-detection range; an output unit that generates and outputs a limit value that greatly limits the operation of the robot the shorter the distance to the object detected by the detection unit; and a robot control unit that controls the robot in accordance with the limit value.

[0010] The robot system according to the present disclosure includes the sensor system according to the present disclosure, and therefore the detection range or non-detection range of the sensor unit can be set appropriately, thereby improving the safety of the robot.

[0011] FIG. 1 is a schematic configuration diagram of a robot system 1. FIG. 2 is a block diagram showing electrical connections of the robot system 1. FIG. 3 is a flowchart showing an example of a detection range setting process. FIG. 4 is an explanatory diagram showing an example of a setting screen Sc before the detection range A is changed. FIG. 5 is an explanatory diagram showing an example of a setting screen Sc after the detection range A is changed. FIG. 6 is a flowchart showing an example of a detection process. FIG. 7 is an explanatory diagram showing a modified example of the setting screen Sc after the detection range A is changed. FIG. 8 is a schematic configuration diagram showing a modified example of the robot system.

[0012] Next, embodiments of the present disclosure will be described with reference to the drawings.

[0013] Fig. 1 is a schematic configuration diagram of a robot system 1. Fig. 2 is a block diagram showing the electrical connections of the robot system 1. As shown in the figure, the robot system 1 of this embodiment includes a robot main body 10, a robot control device 20 that controls the operation of the robot main body 10, a robot safety device 30 that can detect objects (interfering objects such as a worker) around the robot main body 10, and a setting device 40 (see Fig. 2).

[0014] The robot body 10 is a work robot that performs a specified task, and examples thereof include a processing robot that processes a workpiece with a tool, a transport robot that grasps a workpiece with a chuck and transports it to another position, and an assembly robot that grasps a workpiece with a chuck and assembles it to an object.

[0015] As shown in Fig. 1, the robot main body 10 has a base 11 and an articulated arm 12 mounted on the base 11. The articulated arm 12 has a plurality of arms connected in series to the base 11 via joint shafts. As shown in Fig. 2, each joint shaft is provided with a servo motor 15 that drives the corresponding joint shaft and an encoder 16 (rotary encoder) that detects the rotation angle of the corresponding servo motor 15. The robot main body 10 also has an amplifier unit 17 that applies a driving current to each servo motor 15.

[0016] The robot control device 20 includes a control unit 21 configured as a microprocessor including a CPU, ROM, and RAM, and an I / O port 22 for exchanging signals with the control unit 31 of the safety device 30. The robot control device 20 also outputs control signals to the amplifier unit 17 of the robot main body 10 and inputs detection signals from the encoder 16.

[0017] The control unit 21 of the robot control device 20 controls the operation of the robot main body 10 as follows. Specifically, the control unit 21 first sets a target angle for each joint axis of the articulated arm 12 using inverse kinematics based on the target position and target posture of the hand. Next, the control unit 21 acquires the current angle of each joint axis from the corresponding encoder 16 and sets a speed command value for each joint axis using feedback calculations (e.g., proportional-integral calculations or proportional-integral-derivative calculations) based on the difference between the target angle and the current angle. Next, the control unit 21 inputs a speed limit value (described later) from the safety device 30. The control unit 21 then multiplies the speed command value according to the speed limit value to set a target speed. The speed limit value is set, for example, so that the robot speed is more significantly limited as the distance of an object detected by the safety device 30 decreases, i.e., as the object approaches the robot main body 10. For example, if the speed limit value is 1, the target speed is the same as the speed command value. In other words, the operation of the robot main body 10 is not limited. Furthermore, if the speed limit value is 0.5, the target speed is half the speed command value. Furthermore, if the speed limit value is 0, the target speed will be 0 regardless of the speed command value. In other words, the operation of the robot body 10 will be stopped. After setting the target speed, the control unit 21 calculates the current speed from the current angle of the joint axis obtained from the encoder 16, and sets a torque command value to be output from the servo motor 15 by feedback calculation (for example, proportional-integral calculation or proportional-integral-derivative calculation) based on the difference between the calculated current speed and the target speed. Then, the control unit 21 outputs a control signal to the corresponding amplifier unit 17 so that the servo motor 15 outputs a torque corresponding to the set torque command.

[0018] In this embodiment, the robot safety device 30 is attached to the hand of the articulated arm 12. The safety device 30 includes a control unit 31 configured as a microprocessor including a CPU, ROM, and RAM, a sensor unit 32 that monitors the surroundings, and an I / O port 33 for exchanging signals with the control unit 21 of the robot control device 20. Note that the signals exchanged with the control unit 21 of the robot control device 20 may be duplicated.

[0019] In this embodiment, the sensor unit 32 is configured as a MIMO (Multi-Input Multi-Output) radar sensor using the FMCW (Frequency Modulation Continuous Wave) method. The sensor unit 32 has a detection area, for example, defined by a predetermined distance range, horizontal angle range, and vertical angle range from a sensor origin O, which is a predetermined point on the aircraft in three-dimensional space. The sensor unit 32 includes a transmitting antenna that transmits a transmitted chirp, a receiving antenna that receives a wave reflected from a target (reflection point) as a received chirp, a mixer that mixes the transmitted chirp and the received chirp to generate an intermediate frequency signal (IF signal), and a processing unit that processes the IF signal to detect the relative distance to the target (reflection point), the relative velocity to the target (reflection point), and the angle of the target (reflection point). The transmitting antenna transmits multiple transmitted chirps, each spaced at a fixed interval, as one frame. The frequency of the transmitted chirps is modulated to change over time. The processing unit includes an A / D converter that performs A / D conversion on the IF signal generated by the mixer, a DSP that performs Fourier transform processing (FFT processing) on ​​the A / D converted IF signal, and the like. The DSP performs FFT processing (distance FFT processing) on ​​the IF signal in chirp units to obtain a frequency spectrum, and then calculates the relative distance between the sensor unit 32 and the object (reflection point) based on the peak frequency. The DSP also performs FFT processing (velocity FFT processing) on ​​the data after the distance FFT processing in frame units to obtain a frequency spectrum, and then calculates the relative velocity between the sensor unit 32 and the object (reflection point) based on the peak frequency. The DSP also performs FFT processing (angle FFT processing) on ​​the data after the velocity FFT processing in receiving antenna units to obtain a frequency spectrum, and then calculates the angle of the object (reflection point) relative to the sensor unit 32 based on the peak frequency. In this way, the sensor unit 32 obtains point cloud data by measuring the relative distance and relative velocity from the reflection point for each angle.

[0020] The setting device 40 is a device that pre-sets the boundary between a detection range A, which is a range in which a detected result is treated as valid, and a non-detection range B, which is a range in which a detected result is treated as invalid, within the detection area of ​​the sensor unit 32 of the safety device 30. The setting device 40 is not normally connected to the safety device 30, but is connected to the safety device 30 via a cable when setting the detection range A. The setting device 40 is configured as a computer including a CPU 41, a ROM 42, a RAM 43, a storage (e.g., SSD or HDD) 44, and an I / O port 45 for exchanging signals with the control unit 31 of the safety device 30. A dedicated application used to set the detection range A is installed in the storage 44. The setting device 40 is connected to an input device 46, such as a mouse or keyboard, and a display device 47, such as a liquid crystal display or organic EL display. The setting device 40 inputs operation signals from the input device 46 and outputs image signals to the display device 47.

[0021] Next, the operation of the robot system 1 will be described. First, the operation of the setting device 40 will be described. FIG. 3 is a flowchart showing an example of a detection range setting process executed by the CPU 41 of the setting device 40. The detection range setting process is a process for setting a boundary line between a detection range A and a non-detection range within the detection area of ​​the sensor unit 32 prior to the operation of the robot control device 20. The detection range setting process is initiated by launching a detection range setting application while the setting device 40 is connected to the safety device 30. In this embodiment, a first non-detection range B1 and a second non-detection range B2 can be set within the detection area of ​​the sensor unit 32. Note that, hereinafter, when there is no need to particularly distinguish between the first non-detection range B1 and the second non-detection range B2, they will simply be referred to as non-detection range B. In this embodiment, there are two non-detection ranges B, but there may be one or three or more non-detection ranges B.

[0022] When the detection range setting process starts, the CPU 41 first displays a setting screen Sc on the display device 47 (S100). As shown in FIGS. 4 and 5 , the setting screen Sc includes a first setting condition input field C1 for inputting setting conditions for the boundary between the detection range A and the first non-detection range B1, a second setting condition input field C2 for inputting setting conditions for the boundary between the detection range A and the second non-detection range B2, and a detection range display field C3 for displaying the detection range A, the first non-detection range B1, and the second non-detection range B2. The boundary lines in the detection range display field C3 are displayed using a Cartesian coordinate system. Here, the Cartesian coordinate system is a three-dimensional coordinate system with a predetermined point on the sensor unit 32 as the sensor origin O, the left-right direction as the X-axis direction, the front-rear (backward) direction as the Y-axis direction, and the up-down direction as the Z-axis direction. In the initial state, the detection range A coincides with the detection area (the range in which radio waves can be transmitted and received) of the sensor unit 32, as shown in FIG. 4 .

[0023] The operator can set the boundary lines between the detection range A and the first and second non-detection ranges B1 and B2 by inputting boundary line setting conditions on the setting screen Sc.

[0024] The setting conditions for determining the boundary between the detection range A and the first non-detection range B1 include a first left boundary angle α11 and a first right boundary angle α12 in the horizontal direction when determining the boundary, a first lower boundary angle β11 and a first upper boundary angle β12 when determining the boundary in the vertical direction, and a first front boundary distance R11 when determining the boundary in the front-rear (rear) direction. The setting conditions for determining the boundary between the detection range A and the second non-detection range B2 include a second left boundary angle α21 and a second right boundary angle α22 when determining the boundary in the horizontal direction, a second lower boundary angle β21 and a second upper boundary angle β22 when determining the boundary in the vertical direction, and a second front boundary distance R21 when determining the boundary in the front-rear (rear) direction.

[0025] Here, the first left boundary angle α11, the second left boundary angle α21, the first right boundary angle α12, and the second right boundary angle α22 in the horizontal direction are angles between the boundary line determined based on the first left boundary angle α11, the second left boundary angle α21, the first right boundary angle α12, and the second right boundary angle α22 and the Y axis (the axis extending in the front-rear (rear) direction from the sensor unit 32 (sensor origin O)) when the first non-detection range B1 and the second non-detection range B2 are viewed in the XY plane. Note that the first left boundary angle α11, the second left boundary angle α21, the first right boundary angle α12, and the second right boundary angle α22 are negative angles when the boundary line determined based on the first left boundary angle α11, the second left boundary angle α21, the first right boundary angle α12, and the second right boundary angle α22 is positive angles when the boundary line determined based on the first left boundary angle α11, the second left boundary angle α21, the first right boundary angle α12, and the second right boundary angle α22 is located to the left of the Y axis, and are positive angles when the boundary line is located to the right of the Y axis. The first lower boundary angle β11, the second lower boundary angle β21, the first upper boundary angle β12, and the second upper boundary angle β22 are angles formed between the boundary line determined based on the first lower boundary angle β11, the second lower boundary angle β21, the first upper boundary angle β12, and the second upper boundary angle β22 and the Y axis (an axis extending in the front-to-rear direction from the sensor unit 32 (sensor origin O)) when the first non-detection range B1 and the second non-detection range B2 are viewed in the Y-Z plane. The first lower boundary angle β11, the second lower boundary angle β21, the first upper boundary angle β12, and the second upper boundary angle β22 are negative angles when the boundary line determined based on the first lower boundary angle β11, the second lower boundary angle β21, the first upper boundary angle β12, and the second upper boundary angle β22 is positive angles when the boundary line determined based on the first lower boundary angle β11, the second lower boundary angle β21, the first upper boundary angle β12, and the second upper boundary angle β22 is located below the Y axis, and is positive angles when the boundary line is located above the Y axis. The first front boundary distance R11 and the second front boundary distance R21 are the distances from the sensor unit 32 (sensor origin O) to the front ends of the first non-detection range B1 and the second non-detection range B2. The boundary lines determined by these setting conditions are displayed on the XY planar image Im1 and the YZ planar image Im2.

[0026] The boundary between the detection range A and the first non-detection range B1 includes a first left boundary line D11 and a first right boundary line D12 expressed by the following formulas (1) and (2). The boundary lines also include a first bottom boundary line E11 and a first top boundary line E12 expressed by the following formulas (3) and (4). The boundary lines also include a first short-distance boundary line F11 expressed by the following formula (5). Here, the first non-detection range B1 when viewed in the XY plane is the range of the detection area of ​​the sensor unit 32 that is cut out by the first left boundary line D11, the first right boundary line D12, and the first short-distance boundary line F11. The first non-detection range B1 when viewed in the YZ plane is the range of the detection area of ​​the sensor unit 32 that is cut out by the first bottom boundary line E11, the first top boundary line E12, and the first short-distance boundary line F11.

[0027] Y=tan(π / 2-α11)・X...(1) Y=tan(π / 2-α12)・X...(2) Z=tan(β11)・Y...(3) Z=tan(β12)・Y...(4) X^2+Y^2+Z^2=R11^2...(5)

[0028] The boundary between the detection range A and the second non-detection range B2 includes the second left boundary line D21 and the second right boundary line D22 expressed by the following equations (6) and (7). The boundary lines also include the second bottom boundary line E21 and the second top boundary line E22 expressed by the following equations (8) and (9). The boundary lines also include the second short-distance boundary line F21 expressed by the following equation (10). Here, the second non-detection range B2 when viewed in the XY plane is the range of the detection area of ​​the sensor unit 32 that is cut out by the second left boundary line D21, the second right boundary line D22, and the second short-distance boundary line F21. The second non-detection range B2 when viewed in the YZ plane is the range of the detection area of ​​the sensor unit 32 that is cut out by the second bottom boundary line E21, the second top boundary line E22, and the second short-distance boundary line F21.

[0029] Y=tan(π / 2-α21)・X...(6) Y=tan(π / 2-α22)・X...(7) Z=tan(β21)・Y...(8) Z=tan(β22)・Y...(9) X^2+Y^2+Z^2=R21^2...(10)

[0030] The first setting condition input field C1 includes a first distance range input section 50a, a first horizontal angle range input section 60a, and a first vertical angle range input section 70a. The second setting condition input field C2 includes a second distance range input section 50b, a second horizontal angle range input section 60b, and a second vertical angle range input section 70b. Each input section is provided with a slide bar U and sliders S11, S12, S21, and S22 that can be moved left and right by the operator (only sliders S11 and S21 are provided in the first distance range input section 50a and the second distance range input section 50b). Furthermore, the positions of the first left boundary line D11, the second left boundary line D21, the first bottom boundary line E11, the second bottom boundary line E21, the first short distance boundary line F11, and the second short distance boundary line F21 are specified by moving the corresponding sliders S11 and S21 on the slide bar U. Furthermore, the positions of the first right boundary line D12, the second right boundary line D22, the first top boundary line E12, and the second top boundary line E22 are specified by moving the corresponding sliders S12 and S22 on the slide bar U. Each input section includes display input fields Q11, Q21 that display the positions of the sliders S11, S21 as numerical values ​​and allow the numerical values ​​to be input by operating the input device 46 such as a keyboard, and display input fields Q12, Q22 that display the positions of the sliders S12, S22 as numerical values ​​and allow the numerical values ​​to be input by operating the input device 46 such as a keyboard (the first distance range input section 50a and the second distance range input section 50b only have the display input fields Q11, Q21).In addition, the setting screen Sc also includes a save button that is selected when the operator has completed setting the detection range A, and a cancel change button that is selected when the operator cancels the changes to the detection range A and returns the detection range A to its initial state.

[0031] Next, the CPU 41 determines whether the first distance range input unit 50a has been operated (S102). Specifically, the CPU 41 determines whether the slider S11 has been moved relative to the slide bar U in the first distance range input unit 50a, and whether the numerical value displayed in the display input field Q11 has been changed based on the operator's operation. When the CPU 41 determines that the first distance range input unit 50a has been operated, the CPU 41 changes the display of the first distance range input unit 50a and updates the display of the first short-distance boundary line F11 in the XY planar view image Im1 and the YZ planar view image Im2 displayed in the detection range display field C3 (S104). The display of the first distance range input unit 50a is changed by updating the display of the numerical value in the display input field Q11 when the slider S11 is moved, and by moving the slider S11 to a position corresponding to the numerical value in the display input field Q11 when the numerical value in the display input field Q11 is changed.

[0032] When the CPU 41 determines that no operation input has been made to the first distance range input unit 50a, it determines whether or not an operation input has been made to the first horizontal angle range input unit 60a (S106). Specifically, the CPU 41 determines whether or not either the slider S11 or the slider S12 has been moved relative to the slide bar U in the first horizontal angle range input unit 60a, and whether or not any of the numerical values ​​displayed in the display input fields Q11 and Q12 in the first horizontal angle range input unit 60a has been changed based on an operation by the operator. When the CPU 41 determines that an operation input has been made to the first horizontal angle range input unit 60a, it changes the display of either the first left boundary line D11 or the first right boundary line D12, whichever has been operated and input, in the XY planar view image Im1 displayed in the detection range display field C3, while changing the display of the first horizontal angle range input unit 60a (S108). The display of the first horizontal angle range input section 60a is changed by updating the display of the numerical value in the corresponding display input field Q11, Q12 when the sliders S11, S12 are moved, and by moving the corresponding slider S11, S12 to the position corresponding to the numerical value in the display input field Q11, Q12 when the numerical value in the display input field Q11, Q12 is changed.

[0033] When the CPU 41 determines that no operation input has been made to the first horizontal angle range input unit 60a, it determines whether or not an operation input has been made to the first vertical angle range input unit 70a (S110). Specifically, the CPU 41 determines whether or not either the slider S11 or the slider S12 has been moved relative to the slide bar U in the first vertical angle range input unit 70a, and whether or not any of the numerical values ​​displayed in the display input field Q11 or the display input field Q12 in the first vertical angle range input unit 70a has been changed based on an operation by the operator. When the CPU 41 determines that an operation input has been made to the first vertical angle range input unit 70a, it changes the display of either the first lower boundary line E11 or the first upper boundary line E12, whichever has been operated and input, in the YZ planar view image Im2 displayed in the detection range display field C3 (S112). The display of the first vertical angle range input section 70a is changed by updating the display of the numerical value of the corresponding one of the display input fields Q11 and Q12 when the sliders S11 and S12 are moved, and by moving the corresponding one of the sliders S11 and S12 to the position corresponding to the numerical value of the display input field Q11 and Q12 when the numerical value of the display input field Q11 and Q12 is changed.

[0034] When the CPU 41 determines that no operation input has been made to the first vertical angle range input unit 70a, it determines whether or not an operation input has been made to the second distance range input unit 50b (S114). Specifically, the CPU 41 determines whether or not the slider S21 has been moved relative to the slide bar U in the second distance range input unit 50b, and whether or not the numerical value displayed in the display input field Q21 has been changed based on an operation by the operator. When the CPU 41 determines that an operation input has been made to the second distance range input unit 50b, it changes the display of the second distance range input unit 50b and updates the display of the second short-distance boundary line F21 in the XY planar view image Im1 and the YZ planar view image Im2 displayed in the detection range display field C3 (S116). The display of the second distance range input section 50b is changed by updating the display of the numerical value in the display input field Q21 when the slider S21 is moved, and by moving the slider S21 to a position corresponding to the numerical value in the display input field Q21 when the numerical value in the display input field Q21 is changed.

[0035] When the CPU 41 determines that no operation input has been made to the second distance range input unit 50b, it determines whether or not an operation input has been made to the second horizontal angle range input unit 60b (S118). Specifically, the CPU 41 determines whether or not either the slider S21 or the slider S22 has been moved relative to the slide bar U in the second horizontal angle range input unit 60b, or whether or not any of the numerical values ​​displayed in the display input field Q21 or the display input field Q22 in the second horizontal angle range input unit 60b has been changed based on an operation by the operator. When the CPU 41 determines that an operation input has been made to the second horizontal angle range input unit 60b, it changes the display of either the second left boundary line D21 or the second right boundary line D22, whichever has been operated and input, in the XY planar view image Im1 displayed in the detection range display field C3, while changing the display of the second horizontal angle range input unit 60b (S120). The display of the second horizontal angle range input section 60b is changed by updating the display of the numerical value of the corresponding one of the display input fields Q21 and Q22 when the sliders S21 and S22 are moved, and by moving the corresponding one of the sliders S21 and S22 to the position corresponding to the numerical value of the display input field Q21 and Q22 when the numerical value of the display input field Q21 and Q22 is changed.

[0036] When the CPU 41 determines that no operation input has been made to the second horizontal angle range input unit 60b, it determines whether or not an operation input has been made to the second vertical angle range input unit 70b (S122). Specifically, the CPU 41 determines whether or not either the slider S21 or the slider S22 has been moved relative to the slide bar U in the second vertical angle range input unit 70b, and whether or not either the numerical value displayed in the display input field Q21 or the display input field Q22 in the second vertical angle range input unit 70b has been changed based on an operation by the operator. When the CPU 41 determines that an operation input has been made to the second vertical angle range input unit 70b, it changes the display of either the second lower boundary line E21 or the second upper boundary line E22, whichever has been operated and input, in the YZ planar view image Im2 displayed in the detection range display field C3 (S124). The display of the second vertical angle range input section 70b is changed by updating the display of the numerical value of the corresponding one of the display input fields Q21 and Q22 when the sliders S21 and S22 are moved, and by moving the corresponding one of the sliders S21 and S22 to the position corresponding to the numerical value of the display input fields Q21 and Q22 when the numerical value of the display input fields Q21 and Q22 is changed.

[0037] After S104, S108, S112, S116, S120, or S124, the CPU 41 determines whether the input of the setting conditions has been completed (S126). Specifically, the CPU 41 determines whether the save button on the setting screen Sc has been selected. If the CPU 41 determines that the input of the setting conditions has not been completed, the process returns to S102. On the other hand, if the CPU 41 determines that the input of the setting conditions has been completed, the CPU 41 sets the detection range A (S128). Specifically, the CPU 41 sets the detection range A to an area obtained by excluding a first non-detection range B1 defined by the first left boundary line D11, the first right boundary line D12, the first lower boundary line E11, the first upper boundary line E12, and the first short-distance boundary line F11, and a second non-detection range B2 defined by the second left boundary line D21, the second right boundary line D22, the second lower boundary line E21, the second upper boundary line E22, and the second short-distance boundary line F21. The CPU 41 then outputs the set detection range A to the safety device 30 (S130), and ends this process.

[0038] In this way, in the detection range setting process, the boundary between the detection range A and the first non-detection range B1 and the boundary between the detection range A and the second non-detection range B2 can be set by the distance from the sensor unit 32 (sensor origin O) and the horizontal and vertical angles. Therefore, by appropriately setting the distance range, horizontal angle range, and vertical angle range, the detection range A and non-detection range B can be set just right.

[0039] Furthermore, in the detection range setting process, a first non-detection range B1 and a second non-detection range B2 can be set. Therefore, even if there are multiple structures or equipment within the detection area of ​​the sensor unit 32, the area in which they exist can be set as a non-detection range.

[0040] Next, the operation of the safety device 30 when the robot main body 10 (articulated arm 12) is operating will be described. The robot main body 10 operates with the setting device 40 and the safety device 30 separated. In this embodiment, a detection process executed by the control unit 31 (CPU) of the safety device 30 will be described. FIG. 6 is a flowchart showing an example of the detection process. This process detects an object included in a detection range A of the detection area of ​​the sensor unit 32, and is executed at predetermined time intervals (for example, every few ms).

[0041] In the detection process, the control unit 31 acquires the detection value of an object detected within the detection area by the sensor unit 32 as three-dimensional polar coordinate values ​​(distance L, horizontal angle θ, vertical angle φ) (S200). Next, the control unit 31 determines whether the horizontal angle θ is less than the first left boundary angle α11 (S202), whether the horizontal angle θ is greater than the first right boundary angle α12 (S204), and whether the distance L is less than the first front boundary distance R11 (S206). If the control unit 31 makes a negative determination in any of S202 to S206, it determines that the object is included in the first non-detection range B1 in the horizontal direction and terminates the detection process. On the other hand, if the control unit 31 makes a positive determination in any of S202 to S206, it determines that the object is not included in the first non-detection range B1 in the horizontal direction and proceeds to S208.

[0042] Next, the control unit 31 determines whether the vertical angle φ is less than the first lower boundary angle β11 (S208), whether the vertical angle φ is greater than the first upper boundary angle β12 (S210), and whether the distance L is less than the first front boundary distance R11 (S212). If the control unit 31 makes a negative determination in any of S208 to S212, it determines that the object is included in the first non-detection range B1 in the vertical direction and terminates the detection process. On the other hand, if the control unit 31 makes a positive determination in any of S208 to S212, it determines that the object is not included in the first non-detection range B1 in the vertical direction and proceeds to S214.

[0043] Next, the control unit 31 determines whether the horizontal angle θ is less than the second left boundary angle α21 (S214), whether the horizontal angle θ is greater than the second right boundary angle α22 (S216), and whether the distance L is less than the second front boundary distance R21 (S218). If the control unit 31 makes a negative determination in any of S214 to S218, it determines that the object is included in the second non-detection range B2 in the horizontal direction and ends the detection process. On the other hand, if the control unit 31 makes a positive determination in any of S214 to S218, it determines that the object is not included in the second non-detection range B2 in the horizontal direction and proceeds to S220.

[0044] Next, the control unit 31 determines whether the vertical angle φ is less than the second lower boundary angle β21 (S220), whether the vertical angle φ is greater than the second upper boundary angle β22 (S222), and whether the distance L is less than the second front boundary distance R21 (S224). If the control unit 31 makes a negative determination in any of S220 to S224, it determines that the object is within the second non-detection range B2 in the vertical direction and terminates the detection process. On the other hand, if the control unit 31 makes a positive determination in any of S220 to S224, it determines that the object is not within the second non-detection range B2 in the vertical direction and that the detection value is within the detection range A, and proceeds to S226.

[0045] If the control unit 31 determines that the detected value is within the detection range A, it sets a speed limit value such that the shorter the distance L to the object acquired in S200, the greater the restriction on the movement of the robot main body 10 (articulated arm 12) (S226). Then, the control unit 31 outputs the set speed limit value to the robot control device 20 (S228) and ends the detection process. The speed limit value is the ratio of the target speed to the speed command value. The speed limit value is set within a range of 0 to 1, and is set to, for example, 0, 0.25, 0.5, 0.75, or 1. For example, the control unit 31 sets the speed limit value to 0 when the distance L is 0 to 500 mm, sets the speed limit value to 0.25 when the distance L is 500 to 1000 mm, sets the speed limit value to 0.5 when the distance L is 1000 to 1500 mm, sets the speed limit value to 0.75 when the distance L is 1500 to 2000 mm or more, and sets the speed limit value to 1 when the distance L is 2000 mm or more. The control unit 21 of the robot control device 20 multiplies the speed command value by the speed limit value to set the target speed.

[0046] In this way, in the robot system 1, a control command value is generated based on the distance L from the safety device 30, and a target speed is set based on the command value. Therefore, the target speed can be set according to the distance L from the safety device 30.

[0047] Here, the correspondence between the main elements of the embodiment and the main elements of the present disclosure described in the claims will be described. That is, the setting device 40 and safety device 30 of the present embodiment correspond to the sensor system of the present disclosure, the sensor unit 32 corresponds to the sensor unit, the CPU 41 of the setting device 40 that executes the processes of S102, S106, S110, S114, S118, and S122 of the detection range setting process corresponds to the reception unit, the CPU 41 of the setting device 40 that executes the process of S128 of the detection range setting process corresponds to the setting unit, and the control unit 31 of the safety device 30 that executes the processes of S200 to S224 of the detection process corresponds to the detection unit. Furthermore, the control unit 31 of the safety device 30 that executes the processes of S226 and S228 of the detection process corresponds to the output unit. Furthermore, the robot main body 10, the robot control device 20, and the safety device 30 correspond to the robot system, the robot main body 10 corresponds to the robot, and the control unit 21 of the robot control device 20 corresponds to the robot control unit.

[0048] 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.

[0049] In the above-described embodiment, the first short-distance boundary line F11 and the second short-distance boundary line F21 can be set based on the distance from the sensor unit 32 (sensor origin O) to the near ends of the first non-detection range B1 and the second non-detection range B2 (first near boundary distance R11 and second near boundary distance R21). However, as shown in FIG. 7 , the boundaries may be set based on the distance from the sensor unit 32 (sensor origin O) to the far ends of the first non-detection range B1 and the second non-detection range B2 (hereinafter referred to as the first far boundary distance R12 and the second far boundary distance R22). In this case, the first distance range input section 50a of the first setting condition input field C1 and the second distance range input section 50b of the second setting condition input field C2 may include sliders S12 and S22 movable on a slide bar U and display input fields Q12 and Q22 that numerically display the positions of the sliders S12 and S22 and allow numerical values ​​to be entered by operating an input device 46 such as a keyboard. In this case, the CPU 41 may update the display of the first rear boundary line F12 and the second rear boundary line F22 in steps S104 and S116 of the detection range setting process. Note that the first rear boundary line F12 and the second rear boundary line F22 may be expressed in the XY planar image Im1 by the following equations (11) and (12).

[0050] X^2+Y^2=R12^2...(11) X^2+Y^2=R22^2...(12)

[0051] In the above-described embodiment, the safety device 30 is attached to the hand (tip) of the articulated arm 12 of the robot main body 10. However, it may also be attached to the base 11 of the robot main body 10. Furthermore, while the safety device 30 is provided on a stationary robot, it may also be provided on a self-propelled robot. The self-propelled robot may be an arm robot with the above-described articulated arm, or a transport robot. For example, as shown in FIG. 8 , in a mounting line 100 having a plurality of component mounters 101 each having feeder tables arranged in the transport direction of a board and each having a detachable feeder 102, the automatic exchange robot 110 may move along the mounting line 100 to exchange the feeders 102 for each component mounter 101. The safety device 30 is provided on the automatic exchange robot 110, and when an interfering object is detected within the detection range, it outputs a command value to the automatic exchange robot 110 according to the distance to the object. The automatic exchange robot 110 sets a target speed by limiting a speed command value using an input speed limit value.

[0052] In the above-described embodiment, the processes from S200 to S228 of the detection process are executed by the control unit 31 of the safety device 30. However, at least a part of the processes from S200 to S226 may be executed by the control unit 21 of the robot control device 20.

[0053] In the above-described embodiment, the control unit 31 of the safety device 30 sets a speed limit value that limits the movement of the robot main body 10 (articulated arm 12) to a greater extent as the distance L becomes shorter. However, the control unit 31 may set a speed limit value based on the distance L and the speed of the object. In this case, the control unit 31 may set a speed limit value based on the distance L and the speed of the object such that the robot speed is more greatly limited as the time it takes for the object to reach the robot main body 10 (articulated arm 12) becomes shorter.

[0054] In the above-described embodiment, the boundary setting conditions for the detection range A are input by changing the input values ​​in the display input fields Q11 and Q12 in the first setting condition input field C1 or by moving the sliders S11 and S12 relative to the slide bar U. However, the boundary setting conditions between the detection range A and the first non-detection range B1 may also be input by the operator moving the boundary line in the detection range display field C3 using a mouse or the like. In this case, for example, the setting conditions for each boundary line may be input by drag-and-drop in the image displayed in the detection range display field C3. Note that the same applies when inputting the boundary setting conditions between the detection range A and the second non-detection range B2.

[0055] In the above-described embodiment, the setting conditions for the first non-detection range B1 and the second non-detection range B2 are receivable, and the range obtained by excluding the first non-detection range B1 and the second non-detection range B2 from the detection area of ​​the sensor unit 32 is set as the detection range A. However, the setting conditions for the detection range A may be receivable, and the detection range A may be set according to the received setting conditions. In this case, the range obtained by excluding the detection range A from the detection area of ​​the sensor unit 32 may be set as the non-detection range B.

[0056] As described above, the sensor system of the present disclosure accepts the distance range, horizontal angle range, and vertical distance range as setting conditions, and sets the detection range or non-detection range based on the setting conditions. By appropriately setting these ranges, it is possible to set the detection range or non-detection range just right.

[0057] In the sensor system of the present disclosure, the setting unit may set a horizontal detection range or non-detection range based on a combination of the distance range and the horizontal angle range, and set a vertical detection range or non-detection range based on a combination of the distance range and the vertical angle range. In this way, it is possible to set just the right amount of detection range or non-detection range in the horizontal and vertical directions.

[0058] In the sensor system of the present disclosure, the receiving unit may be capable of receiving a plurality of combinations of the distance range and the horizontal angle range, and the setting unit may set the detection range or the non-detection range for the detection area for each combination of the distance range and the horizontal angle range. In this way, a plurality of detection ranges or non-detection ranges can be set in the horizontal direction for one detection area.

[0059] In the sensor system of the present disclosure, the receiving unit may be capable of receiving a plurality of combinations of the distance range and the vertical angle range, and the setting unit may set the detection range or the non-detection range for each combination of the distance range and the vertical angle range for the detection area. In this way, a plurality of detection ranges or non-detection ranges can be set in the vertical direction for one detection area.

[0060] The sensor system of the present disclosure may further include an output unit that generates and outputs a limiting value that limits the robot's movement more severely as the distance to the object detected by the detection unit becomes shorter. In this way, the detected distance to the object can be reflected in the robot's movement, allowing the robot to operate safely.

[0061] The present disclosure may also be embodied as a robot system.

[0062] The specification also discloses the technical idea behind changing "the sensor system according to claim 1 or 2" in claim 4 originally filed to "the sensor system according to any one of claims 1 to 3," as well as the technical idea behind changing "the sensor system according to claim 1 or 2" in claim 5 originally filed to "the sensor system according to any one of claims 1 to 4."

[0063] The present disclosure is applicable to the robot manufacturing industry and the like.

[0064] 1 Robot system, 10 Robot body, 11 Base, 12 Articulated arm, 15 Servo motor, 16 Encoder, 17 Amplifier unit, 20 Robot control device, 21 Control unit, 22 I / O port, 30 Safety device, 31 Control unit, 32 Sensor unit, 33 I / O port, 40 Setting device, 41 CPU, 42 ROM, 43 RAM, 44 Storage, 45 I / O port, 46 Input device, 47 Display device, 50a First distance range input unit, 50b Second distance range input unit, 60a First horizontal angle range input unit, 60b Second horizontal angle range input unit, 70a First vertical angle range input unit, 70b Second vertical angle range input unit, 100 Mounting line, 101 Component mounter, 102 Feeder, 110 Automatic exchange robot, A Detection range, B Non-detection range, B1 B1: First non-detection range, B2: Second non-detection range, C1: First setting condition input field, C2: Second setting condition input field, C3: Detection range display field, D11: First left boundary line, D12: First right boundary line, D21: Second left boundary line, D22: Second right boundary line, E11: First bottom boundary line, E12: First top boundary line, E21: Second bottom boundary line, E22: Second top boundary line, F11: First short distance boundary line, F12: First back boundary line, F21: Second short distance boundary line, F22: Second back boundary line, Im1: XY planar image, Im2: YZ planar image, L: Distance, O: Sensor origin, Q11: Display input field, Q12: Display input field, Q21: Display input field, Q22: Display input field, R11: First front boundary distance, R12: First back boundary distance, R21: Second front boundary distance, R22 Second rear boundary distance, S11, S12, S21, S22 slider, Sc setting screen, U slide bar, α11 first left boundary angle, α12 first right boundary angle, α21 second left boundary angle, α22 second right boundary angle, β11 first lower boundary angle, β12 first upper boundary angle, β21 second lower boundary angle, β22 second upper boundary angle, θ horizontal angle, φ vertical angle.

Claims

1. A sensor system comprising: a sensor unit capable of detecting an object within a detection area defined by a distance from a sensor origin, an angle in a horizontal direction, and an angle in a vertical direction; a reception unit capable of receiving, as setting conditions, a distance range, an angle range in the horizontal direction, and an angle range in the vertical direction with respect to the detection area; a setting unit configured to set a detection range or a non-detection range based on the setting conditions; and a detection unit configured to detect an object within the detection area that is included in the detection range or not included in the non-detection range.

2. The sensor system according to claim 1, wherein the setting unit sets a detection range or a non-detection range in the horizontal direction based on a combination of the distance range and the angle range in the horizontal direction, and sets a detection range or a non-detection range in the vertical direction based on a combination of the distance range and the angle range in the vertical direction.

3. The sensor system according to claim 1 or 2, wherein the reception unit is capable of receiving a plurality of combinations of the distance range and the angle range in the horizontal direction, and the setting unit sets the detection range or the non-detection range for each combination of the distance range and the angle range in the horizontal direction with respect to the detection area.

4. The sensor system according to claim 1 or 2, wherein the reception unit is capable of receiving a plurality of combinations of the distance range and the angle range in the vertical direction, and the setting unit sets the detection range or the non-detection range for each combination of the distance range and the angle range in the vertical direction with respect to the detection area.

5. The sensor system according to claim 1 or 2, further comprising an output unit configured to generate and output a limit value that more greatly limits the operation of the robot as the distance to the object detected by the detection unit is shorter.

6. A robot system comprising: a robot; a sensor unit capable of detecting an object within a detection area defined by a distance from a sensor origin, an angle in a horizontal direction, and an angle in a vertical direction; a reception unit capable of receiving, as setting conditions, a distance range, an angle range in the horizontal direction, and an angle range in the vertical direction from the sensor origin with respect to the detection area; a setting unit configured to set a detection range or a non-detection range based on the setting conditions; a detection unit configured to detect an object within the detection area that is included in the detection range or an object that is not included in the non-detection range; an output unit configured to generate and output a limit value that more greatly restricts the operation of the robot as the distance to the object detected by the detection unit becomes shorter; and a robot control unit configured to control the robot according to the limit value.

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