Visual inspection program creating system, visual inspection program creating device, visual inspection program creating method, and visual inspection program creating program

Abstract

This visual inspection program creating system: acquires input data relating to a plurality of welding beads; estimates the processing time for each of a plurality of steps included in a visual inspection of the plurality of welding beads on the basis of the input data; determines an inspection order of the plurality of welding beads and a movement path of a sensor on the basis of the processing time for each of the plurality of steps; and creates and outputs a visual inspection program for causing a robot that drives the sensor to execute a visual inspection of the plurality of welding beads on the basis of the determined inspection order of the plurality of weld beads and the movement path of the sensor.

Description

Visual inspection program creation system, visual inspection program creation device, visual inspection program creation method, and visual inspection program creation program

[0001] The present disclosure relates to an appearance inspection program creation system, an appearance inspection program creation device, an appearance inspection program creation method, and an appearance inspection program creation program.

[0002] Japanese Patent Application Laid-Open No. 2003-144999 discloses a shape inspection device that can inspect the cross-sectional shape of an arbitrary cross-sectional line by scanning with a slit light once.

[0003] Patent Literature 2 discloses an appearance inspection device that creates and outputs appearance inspection results for a weld bead. The appearance inspection device includes an acquisition unit that acquires input data related to the weld bead, a first judgment unit that performs a first inspection and judgment on the weld bead based on a first judgment criterion set by a user for inspecting the weld bead for defects, k (k: an integer greater than or equal to 1) second judgment units that perform a second inspection and judgment on the weld bead based on a second judgment criterion set by the user for inspecting the weld bead for defects, and a comprehensive judgment unit that determines whether the weld bead is defective. The first judgment unit outputs a first judgment result to the comprehensive judgment unit indicating whether the first inspection result acquired by the first inspection and judgment satisfies the first judgment criterion, and the k second judgment units output second judgment results to the comprehensive judgment unit indicating whether the second inspection result acquired by the second inspection and judgment satisfies the second judgment criterion. The comprehensive judgment unit creates and outputs an appearance inspection result for the weld bead based on the first judgment result and the second judgment result.

[0004] JP 2012-37487 A JP 2021-137848 A

[0005] The present disclosure provides an appearance inspection program creation system, an appearance inspection program creation device, an appearance inspection program creation method, and an appearance inspection program creation program for creating an appearance inspection program that more efficiently performs appearance inspection of workpieces produced by this welding.

[0006] The present disclosure provides a visual inspection program creation system including a sensor that scans multiple weld beads on a workpiece produced by welding, and an inspection control device capable of communicating with the sensor, wherein the inspection control device is configured to acquire input data related to the multiple weld beads, estimate processing times for each of multiple processes included in the visual inspection of the multiple weld beads based on the input data, determine an inspection order for the multiple weld beads and a movement path for the sensor based on the estimated processing times for each of the multiple processes, and create and output a visual inspection program that causes a robot that drives the sensor to perform the visual inspection of the multiple weld beads based on the determined inspection order for the multiple weld beads and the movement path for the sensor.

[0007] The present disclosure also provides an appearance inspection program creation device comprising: an acquisition unit that acquires input data regarding multiple weld beads of a workpiece produced by welding; a determination unit that estimates the processing time for each of multiple processes included in the appearance inspection of the multiple weld beads based on the input data, and determines a combination of an inspection order for the multiple weld beads and a movement path of a sensor that scans the multiple weld beads based on the estimated processing time for each of the multiple processes; and an output unit that creates and outputs an appearance inspection program that causes a robot that drives the sensor to perform the appearance inspection of the multiple weld beads based on the determined inspection order for the multiple weld beads and the movement path of the sensor.

[0008] The present disclosure also provides a method for creating an appearance inspection program performed by a processor, which receives input data regarding multiple weld beads of a workpiece produced by welding, estimates the processing time for each of multiple processes included in the appearance inspection of the multiple weld beads based on the input data, determines the inspection order of the weld beads and the movement path of a sensor that scans the multiple weld beads based on the estimated processing time for each of the multiple processes, and creates and outputs an appearance inspection program that causes a robot that drives the sensor to perform the appearance inspection of the multiple weld beads based on the determined inspection order of the multiple weld beads and the movement path of the sensor.

[0009] The present disclosure also provides a program for creating an appearance inspection program that is executed by a processor, the program causing the processor to perform the following steps: accepting input data regarding multiple weld beads of a workpiece produced by welding; estimating the processing time for each of multiple processes included in the appearance inspection of the multiple weld beads based on the input data; determining the inspection order of the multiple weld beads and the movement path of a sensor that scans the multiple weld beads based on the estimated processing time for each of the multiple processes; and creating and outputting an appearance inspection program that causes a robot that drives the sensor to perform the appearance inspection of the multiple weld beads based on the determined inspection order of the multiple weld beads and the movement path of the sensor.

[0010] According to the present disclosure, it is possible to provide an appearance inspection program creation system, an appearance inspection program creation device, an appearance inspection program creation method, and an appearance inspection program creation program that create an appearance inspection program that more efficiently performs appearance inspection of workpieces produced by this welding.

[0011] FIG. 1 is a schematic diagram illustrating an example of a system configuration of a welding system according to an embodiment of the present disclosure. FIG. 2 is a functional block diagram illustrating an example of the internal configuration of an inspection control device, a robot control device, and a higher-level device according to an embodiment. FIG. 3 is a flowchart illustrating an example of an operation processing procedure of the inspection control device according to the embodiment. FIG. 4 is a diagram illustrating an example 1 of determining an inspection order and a movement path. FIG. 5 is a diagram comparing the processing time of a visual inspection process before and after a change using a visual inspection program according to an embodiment. FIG. 6 is a diagram illustrating an example 2 of determining an inspection order and a movement path. FIG. 7 is a diagram illustrating an example 2 of determining an inspection order and a movement path. FIG. 8 is a diagram illustrating an example 2 of determining an inspection order and a movement path. FIG. 9 is a diagram illustrating an example of grouping weld beads according to a modified embodiment. FIG. 10 is a diagram illustrating an example of a conventional visual inspection process and the processing time of the entire visual inspection process.

[0012] (Background to the present disclosure) As disclosed in Patent Document 1, there is a technology for automatically performing a visual inspection of weld beads to determine whether a workpiece produced by actual welding is a conforming product based on feature quantities (e.g., bead width, bead height, etc.) related to the shape of the weld bead. In the visual inspection of weld beads, multiple processes are performed for each weld bead based on an inspection order for multiple weld beads arbitrarily set by an operator, such as moving to the weld bead to be visually inspected, scanning the external shape of the weld bead, and visually inspecting the weld bead based on point cloud data of the weld bead obtained by scanning. Here, with reference to FIG. 10 , an example of a conventional method for improving the efficiency of the visual inspection process will be described.

[0013] FIG. 10 is a diagram showing an example of a conventional appearance inspection process and the processing time of the entire appearance inspection process.

[0014] The time chart for visual inspection shown in <Before Change> in Figure 10 is a time chart for when the process of moving a sensor by a welding robot, the process of scanning the external shape of the weld bead by the sensor, and the process of analyzing the point cloud data by an inspection control device (i.e., inspection) are performed serially for each of three weld beads A, B, and C. Note that "Move + Scan A" and "Inspect A" are processes corresponding to weld bead A. "Move + Scan B" and "Inspect B" are processes corresponding to weld bead B. "Move + Scan C" and "Inspect C" are processes corresponding to weld bead C. In such a case, the time required to perform the visual inspection procedure is processing time T11.

[0015] Furthermore, the time chart for the visual inspection shown in <After Change> in Figure 10 shows a time chart when the process of moving the sensor by the welding robot for each of the three weld beads A, B, and C and the process of scanning the external shape of the weld bead by the sensor, and the process of analyzing the point cloud data by the inspection control device for each of the three weld beads A, B, and C (i.e., the inspection process) are executed in parallel.

[0016] In the appearance inspection procedure shown in <After Change> in FIG. 10 , while moving to and scanning the next weld bead (e.g., weld bead B), analysis (inspection) of the point cloud data of the previously scanned weld bead (e.g., weld bead A) is performed. This allows the time required to perform the appearance inspection procedure to be shortened compared to the appearance inspection procedure shown in <Before Change>. In this case, the time required to perform the appearance inspection procedure shown in <After Change> is processing time T21, which is shortened by a reduction time T22 compared to processing time T11 required to perform the appearance inspection procedure shown in <Before Change>.

[0017] As described above, by parallel processing of the steps (movement step and scanning step) performed by the welding robot and the step (inspection step) performed by the inspection control device in the visual inspection process, the overall processing time of the visual inspection process can be shortened. However, there is a limit to the time that can be shortened by this method. Furthermore, as described above, the order in which the visual inspection of the weld beads is performed is determined arbitrarily by the operator. For this reason, it is difficult to shorten the time required to move to the weld beads to be visually inspected and the time required to wait for the weld beads to be scanned in the visual inspection process.

[0018] Therefore, in the following embodiments, examples of an appearance inspection program creation system, an appearance inspection program creation device, an appearance inspection program creation method, and an appearance inspection program creation program that perform more efficient appearance inspection of workpieces produced by actual welding are described.

[0019] <Embodiments> Hereinafter, with reference to the drawings as appropriate, embodiments specifically disclosing the visual inspection program creation system, visual inspection program creation device, visual inspection program creation method, and visual inspection program creation program according to the present disclosure will be described in detail. However, more detailed explanation than necessary may be omitted. For example, detailed explanations of already well-known matters and redundant explanations of substantially identical configurations may be omitted. This is to avoid unnecessary redundancy in the following explanation and to facilitate understanding by those skilled in the art. Note that the accompanying drawings and the following description are provided to enable those skilled in the art to fully understand the present disclosure and are not intended to limit the subject matter recited in the claims.

[0020] The visual inspection device according to this embodiment generates a program (hereinafter referred to as the "visual inspection program") for causing a welding robot to perform a visual inspection of the weld beads of the workpiece produced by main welding.

[0021] Hereinafter, the object to be welded (e.g., metal) is defined as the "original workpiece," and the object produced (manufactured) by the main welding is defined as the "workpiece." Note that the "workpiece" is not limited to a workpiece produced by one main welding, but may be a composite workpiece produced by two or more main weldings. Furthermore, the process of producing a workpiece by joining an original workpiece with another original workpiece using a welding robot is defined as "main welding," and the process of inspecting the workpiece to detect defects is defined as "visual inspection."

[0022] (Configuration of Welding System) FIG. 1 is a schematic diagram showing an example of a system configuration of a welding system 100 according to an embodiment of the present disclosure.

[0023] Welding system 100 includes host device 1 connected to external storage ST, input interface UI1, and monitor MN1, robot control device 2, inspection control device 3, sensor 4, and welding robot MC1. For ease of understanding, the following description will be given assuming that the welding robot MC1 performs the main welding and appearance inspection processes.

[0024] 1 shows only one pair of one robot control device 2 and one welding robot MC1, but multiple pairs may be provided. Also, in FIG. 1, the sensor 4 is shown as a separate body from the welding robot MC1, but it may be provided integrally with the welding robot MC1 (see FIG. 2).

[0025] The host device 1 is a device including a computer that controls the start and completion of main welding performed by the welding robot MC1 via the robot control device 2. For example, the host device 1 reads welding-related information that has been input or set in advance by a user (e.g., a welding operator or a system administrator) from the external storage ST, and uses this welding-related information to generate a main welding execution command that includes the contents of the welding-related information and transmits it to the corresponding robot control device 2. Furthermore, when the main welding by the welding robot MC1 is completed, the host device 1 receives a main welding completion report from the robot control device 2 indicating that the main welding by the welding robot MC1 has been completed, updates the status of the corresponding workpiece to a status indicating that the main welding has been completed, and records the updated status in the external storage ST.

[0026] The execution command for main welding described above does not necessarily have to be generated by the higher-level device 1, but may be generated by, for example, an operation panel (e.g., a Programmable Logic Controller (PLC)) of equipment in a factory or the like where main welding is performed, or an operation panel (e.g., a Teach Pendant (TP)) of the robot control device 2. The teach pendant (TP) is a device for operating the welding robot MC1 connected to the robot control device 2.

[0027] Furthermore, the host device 1 comprehensively controls the start and completion of the visual inspection using the robot control device 2, the inspection control device 3, and the sensor 4. For example, when the host device 1 receives a report of the completion of main welding from the robot control device 2, it generates an instruction to execute a visual inspection (bead inspection) of the workpiece produced by the welding robot MC1 and sends it to each of the robot control device 2 and the inspection control device 3. When the visual inspection is completed, the host device 1 receives an appearance inspection report indicating that the appearance inspection has been completed from the inspection control device 3, updates the status of the corresponding workpiece to a status indicating that the appearance inspection has been completed, and records this in the external storage ST.

[0028] Here, the welding-related information is information indicating the details of the main welding to be performed by the welding robot MC1, and is created in advance for each main welding process and registered in the external storage ST. The welding-related information includes, for example, the number of original workpieces to be used in the main welding, workpiece information including the ID (identification information), name, and welding location of the original workpieces to be used in the main welding, the scheduled execution date of the main welding, the number of workpieces to be welded, and various welding conditions for the main welding. Note that the welding-related information does not have to be limited to the data of the above items.

[0029] Based on the execution command for main welding sent from the host device 1, the robot control device 2 causes the welding robot MC1 to start performing main welding using the original workpiece specified in the execution command. Note that the above-mentioned welding-related information does not necessarily have to be managed by the host device 1 with reference to the external storage ST, but may also be managed, for example, by the robot control device 2. In this case, since the robot control device 2 can grasp the state when main welding is completed, the actual execution date of the welding process may be managed instead of the scheduled execution date of the welding process among the welding-related information. Note that, although the type of main welding is not important in this specification, for ease of understanding, a process of joining multiple original workpieces to produce one workpiece will be described as an example.

[0030] The higher-level device 1 is connected to the monitor MN1, input interface UI1, and external storage ST so as to enable data input and output, and is also connected to the robot control device 2 so as to enable data communication. The higher-level device 1 may be a terminal device P1 that integrally includes the monitor MN1 and input interface UI1, or may also integrally include the external storage ST. In this case, the terminal device P1 is a personal computer (hereinafter referred to as "PC") used by a user prior to the execution of the actual welding. The terminal device P1 is not limited to the above-mentioned PC, and may also be a computer device with communication capabilities, such as a smartphone or tablet terminal.

[0031] The monitor MN1 may be configured using a display device such as a liquid crystal display (LCD) or an organic electroluminescence (OLED). The monitor MN1 may display, for example, a notification screen indicating that main welding has been completed, a notification screen indicating that the visual inspection has been completed, and a notification screen indicating the results of the visual inspection, which are output from the higher-level device 1. Alternatively, or in addition to the monitor MN1, a speaker (not shown) may be connected to the higher-level device 1, and the higher-level device 1 may output audio via the speaker, notifying the user that main welding has been completed, notifying the user that the visual inspection has been completed, and indicating the results of the visual inspection.

[0032] The input interface UI1 is a user interface that detects input operations by the user and outputs the results to the higher-level device 1, and may be configured using, for example, a mouse, a keyboard, or a touch panel. The input interface UI1 receives, for example, input operations when the user creates welding-related information, and receives input operations when sending a command to the robot control device 2 to perform the actual welding.

[0033] The external storage ST is configured using, for example, a hard disk drive or a solid state drive. The external storage ST stores, for example, welding-related information data created for each main welding, the status (production status) of the workpiece produced by the main welding, and workpiece information of the workpiece (see the above description).

[0034] The robot control device 2 is connected to the higher-level device 1 so as to be able to communicate data, and is also connected to the welding robot MC1 so as to be able to communicate data. When the robot control device 2 receives a command to perform main welding sent from the higher-level device 1, it controls the corresponding welding robot MC1 to perform main welding based on the command. When the robot control device 2 detects the completion of main welding, it generates a main welding completion report to the effect that main welding has been completed, and notifies the higher-level device 1 of this.

[0035] Furthermore, when the robot control device 2 receives an instruction to perform an appearance inspection sent from the higher-level device 1, it controls the welding robot MC1 (see FIG. 2) equipped with the sensor 4 in accordance with the appearance inspection program created by the inspection control device 3, and performs an appearance inspection of the corresponding workpiece Wk based on the execution instruction. An appearance inspection report indicating that the appearance inspection has been completed is sent from the inspection control device 3 to the higher-level device 1, but it may also be sent to the higher-level device 1 by the robot control device 2 itself, or from the robot control device 2 that has received an instruction from the inspection control device 3.

[0036] The welding robot MC1 is connected to the robot control device 2 so as to be able to communicate data with the robot control device 2. The welding robot MC1 performs main welding or visual inspection as instructed by the higher-level device 1 under the control of the corresponding robot control device 2. Note that, although the present embodiment describes an example in which the welding robot MC1 is capable of performing main welding and visual inspection, the present disclosure is not limited thereto. The welding system 100 may be configured to include different robots, namely, a main welding robot provided for main welding and an inspection robot provided for visual inspection.

[0037] The inspection control device 3 is connected to enable data communication with each of the host device 1, the robot control device 2, and the sensor 4. When the inspection control device 3 receives a command to perform a visual inspection sent from the host device 1, it performs, together with the sensor 4, a visual inspection of the welded portion of the workpiece produced by the welding robot MC1 (for example, an inspection to determine whether the weld bead formed on the workpiece satisfies predetermined welding standards).

[0038] The sensor 4 is connected to the inspection control device 3 so as to be able to communicate data. The sensor 4 scans the weld bead of the workpiece Wk in response to the driving of the manipulator 200 (see FIG. 2 ) under the control of the robot control device 2, acquires data (for example, point cloud data described later) that can identify the three-dimensional shape of the weld bead of the workpiece Wk, and transmits the data to the inspection control device 3.

[0039] The monitor MN2 may be configured using a display device such as an LCD or an organic EL display. The monitor MN2 displays, for example, a screen output from the inspection control device 3, which indicates a notification that the visual inspection has been completed, or a screen showing the notification and the results of the visual inspection (for example, the results of the comprehensive judgment described in the background art).

[0040] FIG. 2 is a functional block diagram showing an example of the internal configuration of the inspection control device 3, the robot control device 2, and the higher-level device 1 according to the embodiment.

[0041] For ease of understanding, the monitors MN1 and MN2 and the input interface UI1 are not shown in Fig. 2. The workpiece Wk shown in Fig. 2 may be an original workpiece that is placed before main welding is performed, or may be a workpiece that is the target of visual inspection (i.e., a workpiece produced by main welding).

[0042] Welding robot MC1 performs various processes, such as main welding and visual inspection, instructed by host device 1 under the control of robot control device 2. In the main welding process, welding robot MC1 performs, for example, arc welding. However, welding robot MC1 may also perform other types of welding besides arc welding (e.g., laser welding or gas welding). In this case, although not shown, a configuration in which a laser head is connected to a laser oscillator via an optical fiber may be used instead of welding torch 400. Welding robot MC1 is configured to include at least manipulator 200, wire feeder 300, welding wire 301, and welding torch 400.

[0043] Manipulator 200 has a multi-joint arm, and drives the arm by moving each joint of the arm based on a control signal from robot control unit 25 of robot control device 2. In this way, manipulator 200 can change the positional relationship between workpiece Wk and welding torch 400 or the positional relationship between workpiece Wk and sensor 4 by driving the arm.

[0044] The wire feeder 300 controls the feed speed of the welding wire 301 based on a control signal from the robot control device 2 .

[0045] Welding wire 301 is held by welding torch 400. When power is supplied to welding torch 400 from power supply device 500, an arc is generated between the tip of welding wire 301 and workpiece Wk, and arc welding is performed. For the sake of convenience, illustrations and descriptions of the configuration for supplying shielding gas to welding torch 400 are omitted.

[0046] The host device 1 uses welding-related information input or set in advance by the user to generate execution commands for various processes of the actual welding and the visual inspection, and sends them to the robot control device 2. The execution command for the visual inspection is sent to both the robot control device 2 and the inspection control device 3. The host device 1 is configured to include at least a communication unit 10, a processor 11, and a memory 12.

[0047] The communication unit 10 is connected to each of the robot control device 2, the inspection control device 3, and the external storage ST so as to be able to communicate data with them. The communication unit 10 sends execution commands for various processes of main welding or visual inspection generated by the processor 11 to the robot control device 2, or to the robot control device 2 and the inspection control device 3. The communication unit 10 receives a main welding completion report and a visual inspection report sent from the robot control device 2 or the inspection control device 3, and outputs them to the processor 11.

[0048] The processor 11 is configured using, for example, a Central Processing Unit (hereinafter referred to as "CPU") or a Field Programmable Gate Array (hereinafter referred to as "FPGA"), and performs various processes and controls in cooperation with the memory 12. Specifically, the processor 11 references a program stored in the memory 12 and executes the program to realize the functions of the cell control unit 13.

[0049] The memory 12 includes, for example, a random access memory (hereinafter referred to as "RAM") as a work memory used when executing the processing of the processor 11, and a read only memory (hereinafter referred to as "ROM") that stores a program that defines the processing of the processor 11. The RAM temporarily stores data generated or acquired by the processor 11. The ROM stores programs that define the processing of the processor 11. The memory 12 also stores welding-related information data read from the external storage ST, workpiece status data, and workpiece information (see the above description) of the workpiece sent from the robot control device 2.

[0050] The cell control unit 13 generates an execution command for performing main welding or a visual inspection of the workpiece based on the welding-related information stored in the external storage ST. The cell control unit 13 may generate a different execution command for each main welding process performed by the welding robot MC1. The main welding execution command or the visual inspection program execution command generated by the cell control unit 13 is transmitted via the communication unit 10 to the corresponding robot control device 2, or to both the robot control device 2 and the inspection control device 3.

[0051] The robot control device 2 controls the corresponding welding robot MC1 (e.g., the sensor 4, the manipulator 200, the wire feeder 300, and the power supply device 500) based on a command to perform actual welding or visual inspection sent from the higher-level device 1.

[0052] The robot control device 2 includes at least a communication unit 20 , a processor 21 , and a memory 22 .

[0053] The communication unit 20 is connected to each of the host device 1, the inspection control device 3, and the welding robot MC1 so as to be able to communicate data. Although the illustration is simplified in Fig. 2, data is transmitted and received between the robot control unit 25 and the manipulator 200, between the robot control unit 25 and the wire feeder 300, and between the power supply control unit 26 and the power supply device 500 via the communication unit 20. The communication unit 20 receives a command to perform main welding or visual inspection transmitted from the host device 1.

[0054] Here, the workpiece information includes not only the ID of the workpiece, but also at least the ID, name, and welding location of the original workpiece used in the main welding, and the welding conditions for performing the main welding. The welding conditions include, for example, the material and thickness of the original workpiece, the material and diameter of the welding wire 301, the type of shielding gas, the flow rate of the shielding gas, the set average value of the welding current, the set average value of the welding voltage, the feed speed and feed amount of the welding wire 301, the number of welds, and the welding time. In addition to these, the information may also include, for example, information indicating the type of main welding (e.g., TIG welding (Tungsten Inert Gas Welding), MAG welding (Metal Active Gas Welding), or pulse welding), as well as the movement speed and movement time of the manipulator 200.

[0055] Processor 21 is configured using, for example, a CPU or FPGA, and performs various processes and controls in cooperation with memory 22. Specifically, processor 21 references the programs stored in memory 22 and executes the programs to realize the functions of welding program creation unit 23, calculation unit 24, robot control unit 25, and power supply control unit 26.

[0056] The memory 22 includes, for example, a RAM serving as a work memory used when executing the processing of the processor 21, and a ROM for storing a program that defines the processing of the processor 21. Data generated or acquired by the processor 21 is temporarily stored in the RAM. The ROM has written therein a program that defines the processing of the processor 21. The memory 22 also stores data on commands to perform main welding or visual inspection transmitted from the higher-level device 1, and data on workpiece information for the workpieces Wk produced by main welding. The memory 22 also stores a main welding program for main welding executed by the welding robot MC1. The main welding program here is a program that defines specific procedures (steps) for main welding, such as joining multiple original workpieces, using welding conditions for main welding.

[0057] Based on the execution command for main welding received from higher-level device 1 via communication unit 20, main welding program creation unit 23 generates a main welding program for main welding to be performed by welding robot MC1 using workpiece information (e.g., ID, name, and welding location of the main workpiece) for each of the multiple original workpieces included in the execution command. The main welding program may include various parameters, such as welding current, welding voltage, offset amount, welding speed, and attitude of welding torch 400, for controlling power supply device 500, manipulator 200, wire feeder 300, welding torch 400, etc., during main welding.

[0058] The calculation unit 24 performs calculations of parameters for controlling the welding robot MC1 (specifically, the manipulator 200, the wire feeder 300, and the power supply unit 500) controlled by the robot control unit 25 based on the welding program or the visual inspection program.

[0059] Robot control unit 25 generates control signals for driving welding robot MC1 (specifically, manipulator 200, wire feeder 300, and power supply unit 500) based on the welding program or the appearance inspection program. Robot control unit 25 transmits the generated control signals to welding robot MC1.

[0060] Power supply control unit 26 drives power supply device 500 based on the actual welding program generated by actual welding program generation unit 23 and the calculation results of calculation unit 24.

[0061] The inspection control device 3 creates a visual inspection program for the workpiece Wk produced by main welding, and performs a visual inspection of the workpiece Wk based on a visual inspection execution command sent from the higher-level device 1. The visual inspection is, for example, an inspection of whether or not the weld bead formed on the workpiece satisfies predetermined welding standards (e.g., quality standards). The inspection control device 3 is configured to include at least a communication unit 30, a processor 31, a memory 32, and an inspection result storage unit 33.

[0062] The communication unit 30 is connected to each of the host device 1, the robot control device 2, and the sensor 4 so as to be able to communicate data with them. Although the illustration is simplified in Fig. 2, data is sent and received between the shape detection control unit 34 and the sensor 4 via the communication unit 30. The communication unit 30 receives a command to execute an appearance inspection sent from the host device 1. The communication unit 30 transmits an appearance inspection program created by the appearance inspection program creation unit 36 ​​to the robot control device 2.

[0063] The processor 31 is configured using, for example, a CPU or FPGA, and performs various processes and controls in cooperation with the memory 32. Specifically, the processor 31 references a program stored in the memory 32 and executes the program to realize the functions of a shape detection control unit 34, a data processing unit 35, and an appearance inspection program creation unit 36.

[0064] The memory 32 includes, for example, a RAM serving as a work memory used when executing the processing of the processor 31, and a ROM for storing a program that defines the processing of the processor 31. Data generated or acquired by the processor 31 is temporarily stored in the RAM. The ROM has written therein a program that defines the processing of the processor 31. The memory 32 also stores data of an instruction to execute a visual inspection of the workpiece transmitted from the higher-level device 1, and data of workpiece information about the workpiece Wk. The memory 32 also stores data of a visual inspection program created by the visual inspection program creation unit 36. The visual inspection program is a program that defines specific procedures (steps) for visual inspection of each of multiple weld beads of a workpiece manufactured using the same welding program.

[0065] The inspection result storage unit 33 is configured using, for example, a hard disk or a solid state drive. The inspection result storage unit 33 stores data indicating the results of an appearance inspection of the welded portion (weld bead) of the workpiece Wk, which is executed based on the appearance inspection program, as an example of data generated or acquired by the processor 31.

[0066] Shape detection control unit 34 acquires input data related to the shape of the weld bead (e.g., point cloud data from which the three-dimensional shape of the weld bead can be identified) transmitted from sensor 4. When sensor 4 reaches a position where it can capture an image of the weld bead (in other words, where it can detect the three-dimensional shape of the welded portion) in response to driving of manipulator 200 by robot control device 2 described above, shape detection control unit 34 causes sensor 4 to acquire input data related to the shape of the weld bead (e.g., point cloud data from which the three-dimensional shape of the weld bead can be identified), for example, by irradiating a laser beam from sensor 4. When shape detection control unit 34 receives the input data acquired by sensor 4 (see the above description), it outputs the input data to data processing unit 35.

[0067] When the data processing unit 35 receives input data (see the above explanation) regarding the shape of the weld bead from the shape detection control unit 34, it converts the data into a data format suitable for creating an appearance inspection program or a data format suitable for appearance inspection.

[0068] For example, as a data format conversion process, the data processing unit 35 may perform a correction process to remove unnecessary point cloud data (e.g., noise) contained in the input data (i.e., point cloud data), and an edge enhancement correction process to emphasize the peripheral portion of the weld bead in order to highlight the position and shape of the weld bead.

[0069] The visual inspection program creation unit 36 ​​creates a visual inspection program for the workpiece Wk to be executed by the welding robot MC1 based on the position, size, etc. of the weld bead based on input data obtained by visual inspection of the workpiece Wk by the sensor 4. The visual inspection program may include various parameters for controlling the manipulator 200, the sensor 4, etc. during the visual inspection. The visual inspection program may be stored in the processor 31 or in the RAM in the memory 32.

[0070] The sensor 4 is, for example, a three-dimensional shape sensor, and is attached to the tip of the welding robot MC1. The sensor 4 generates a plurality of point cloud data that can identify the shape of a weld bead (weld point) on the workpiece Wk (for example, workpiece). The sensor 4 transmits the generated point cloud data that can identify the three-dimensional shape of the weld point to the inspection control device 3.

[0071] In addition, if sensor 4 is not attached to the tip of welding robot MC1 but is arranged separately from welding robot MC1, it may be composed of a laser light source (not shown) and a camera (not shown). The laser light source is configured to scan the position of the weld bead (weld point) on the workpiece Wk based on position information of the weld bead (weld point) transmitted from inspection control device 3. The camera is positioned to be able to capture an image of an imaging area including the periphery of the weld point, and captures the reflection trajectory of the laser light reflected from the weld point (i.e., the shape line of the weld point). In such a case, sensor 4 transmits shape data of the weld point (in other words, image data of the weld bead) based on the laser light captured by the camera to inspection control device 3. In addition, the above-mentioned camera is configured to have at least a lens (not shown) and an image sensor (not shown). The image sensor is a solid-state imaging device such as a CCD (Charge Coupled Device) or a CMOS (Complementary Metal Oxide Semiconductor), and converts an optical image formed on an imaging surface into an electrical signal.

[0072] (Procedure for Creating an Appearance Inspection Program) Next, a method for creating an appearance inspection program will be described with reference to FIG.

[0073] FIG. 3 is a flowchart showing an example of an operation processing procedure of the inspection control device 3 according to the embodiment.

[0074] The welding robot MC1 determines an inspection start position for one of the multiple weld beads produced by main welding (St11).

[0075] Welding robot MC1 moves sensor 4 to the inspection start position, scans the weld bead (St12), and determines the inspection end position, which is the scanning end position of the weld bead (St13). Welding robot MC1 performs the processes of steps St11 to St13 for each of the multiple weld beads. Note that in steps St11 to St13, welding robot MC1 only needs to be able to scan each of the multiple weld beads generated by main welding with sensor 4, and may scan each of the multiple weld beads with sensor 4 based on any program created in advance.

[0076] After performing the processing of steps St11 to St13, the welding robot MC1 determines whether the weld bead that was the target of the processing of steps St11 to St13 is the last weld bead for which the processing of steps St11 to St13 has not been performed (St14).

[0077] If welding robot MC1 determines that the weld bead for which steps St11 to St13 have been executed is the last weld bead for which steps St11 to St13 have not been executed (YES in St14), it proceeds to step St 15. On the other hand, if welding robot MC1 determines that the weld bead for which steps St11 to St13 have been executed is not the last weld bead for which steps St11 to St13 have not been executed (NO in St15), it returns to step St11, selects one of the weld bead for which steps St11 to St13 have not been executed, and starts step St11.

[0078] Based on the determined inspection start position and inspection end position of the weld bead, the inspection control device 3 estimates the processing time of the movement process in which the sensor 4 is moved to the position of each weld bead, the processing time of the scanning process in which the sensor 4 scans the weld bead, and the processing time of the inspection process in which the point cloud data of the weld bead is inspected (analyzed).

[0079] The inspection start position and inspection end position may be determined along the welding direction during actual welding, and the movement direction (scanning direction) of the sensor 4 determined by the movement path in step St19 described later may be the direction from the inspection end position toward the inspection start position, i.e., the opposite direction to the welding direction.

[0080] The inspection control device 3 acquires the three-dimensional coordinate system set for the welding robot MC1, information on the orientation of the sensor 4 attached to the welding robot MC1, CAD data for the workpiece Wk, the three-dimensional shape of the original workpiece, and information on the obstacle (St15). Note that the obstacle here refers to production equipment for producing the workpiece Wk, such as a jig or a fixing table for the workpiece Wk, and is an object that obstructs the movement of the welding robot MC1 or the sensor 4. The information on the obstacle is information such as the position, size, or shape of the obstacle on the three-dimensional coordinate system.

[0081] Inspection control device 3 creates an inspection program for performing an appearance inspection of each of the multiple weld beads corresponding to each weld section generated by main welding, based on the determined inspection start position and inspection end position for each of the multiple weld beads, the acquired coordinate system of welding robot MC1, information on the orientation of sensor 4, CAD data of workpiece Wk, the three-dimensional shape of the original workpiece, and information on obstacles (St16). Here, the inspection program includes a movement process for moving sensor 4, a scanning process for scanning the weld bead with sensor 4, and an inspection process for inspecting (analyzing) point cloud data of the weld bead, all of which are generated for each weld bead.

[0082] The inspection control device 3 obtains the inspection start position and the inspection end position for each weld bead corresponding to each welding section from the created inspection program (St17), and optimizes the inspection order and movement path of the sensor 4 using deep learning that optimizes the inspection order of the multiple weld beads and the movement path of the sensor 4. As a result, the inspection control device 3 determines the inspection order of the multiple weld beads (St18), and generates a movement path of the sensor 4 for scanning each of the multiple weld beads during the visual inspection based on the determined inspection order (St19). Note that optimization here refers to a process that further shortens the overall processing time for the visual inspection, and includes, for example, a process of generating a movement path that minimizes the difference between the inspection time and the movement time for each weld bead in order to further shorten the overall processing time for the visual inspection.

[0083] Specifically, in the optimization process for the weld bead inspection order and movement paths, the inspection control device 3 breaks down all the weld bead inspection programs included in the inspection program into separate inspection programs for each weld bead. The inspection control device 3 estimates the processing time and waiting time for each process included in the divided inspection program for each weld bead based on the estimated distance and travel time to each weld bead, the scan time of the weld bead by the sensor 4, and the inspection time for inspecting (analyzing) the point cloud data of the weld bead. The inspection control device 3 rearranges the divided inspection programs based on the inspection time of each weld bead and the travel time or scan time between each weld bead to minimize or shorten the overall processing time for the visual inspection of the workpiece Wk, and determines the inspection order and movement path for each weld bead. For example, if the inspection control device 3 determines, based on the estimated travel time, scan time, inspection time, etc., that there is a weld bead that will take a long inspection time, the inspection control device 3 determines the inspection order so that movement to a weld bead located farther away is performed while the inspection of the weld bead is being performed, rather than a nearby weld bead, thereby improving the efficiency of movement between weld beads.

[0084] The scanning direction of the weld bead determined by the movement path may be opposite to the welding direction of the actual welding. In such a case, the inspection control device 3 determines the inspection position of the weld bead corresponding to the welding start point of the weld line as the inspection end point, and determines the inspection position of the weld bead corresponding to the welding end point of the weld line as the inspection start point.

[0085] Based on the generated movement path of the sensor 4 and the information on the obstacle, the inspection control device 3 determines whether or not the sensor 4 will interfere with the obstacle when the sensor 4 moves along the movement path (St20).

[0086] If the inspection control device 3 determines that the sensor 4 will interfere with an obstacle (St20, YES), it generates an avoidance path for avoiding the obstacle on the generated movement path, or it discards the information on the generated movement path and generates a new inspection order for the multiple weld beads, and regenerates another movement path based on the new inspection order for the multiple weld beads (St21). Note that the inspection control device 3 may regenerate another movement path while leaving the inspection order for the multiple weld beads unchanged.

[0087] When the generation of the avoidance path is executed in step St21, the inspection control device 3 again determines whether or not the sensor 4 will interfere with an obstacle during movement along a movement path including the avoidance path (St20). Furthermore, when the regeneration of another movement path is executed in step St21, the inspection control device 3 again determines whether or not the sensor 4 will interfere with an obstacle during movement along the regenerated other movement path (St20).

[0088] On the other hand, if the inspection control device 3 determines that the sensor 4 will not interfere with an obstacle (St20, NO), it creates a visual inspection program based on the generated movement path (St22).

[0089] The inspection control device 3 transmits the generated appearance inspection program to the robot control device 2, and causes the robot control device 2 and the welding robot MC1 to start (execute) an appearance inspection of multiple weld beads of the workpiece Wk based on the control of the robot control device 2 (St23).

[0090] In addition, in the above-mentioned step St21, the inspection control device 3 may execute both generation of an avoidance path and regeneration of another movement path. In such a case, the inspection control device 3 may compare the processing time of the entire appearance inspection when the appearance inspection is performed using a movement path including the avoidance path with the processing time of the entire appearance inspection when the appearance inspection is performed using another movement path, and select the inspection order and movement path that shortens the processing time of the entire appearance inspection.

[0091] As described above, the inspection control device 3 in this embodiment can create a visual inspection program for the workpiece Wk that can further reduce the time (processing time) required to perform the entire visual inspection.

[0092] (Example 1 of Determining the Inspection Order and Movement Path of Weld Beads) Next, with reference to FIGS. 4 and 5, Example 1 of Determining the Inspection Order and Movement Path of Weld Beads will be described. FIG.

[0093] Fig. 4 is a diagram showing an example 1 of determining the inspection order and movement path. Fig. 5 is a diagram comparing the processing time of the appearance inspection process before and after the change by the appearance inspection program of this embodiment.

[0094] In Example 1 of determining the inspection order and movement paths of multiple weld beads shown in FIG. 4, an example is shown in which the overall processing time for visual inspection of the workpiece Wk is optimized based on the inspection order and movement paths shown in <Before Change>. Note that the inspection order and movement paths of multiple weld beads shown in FIG. 4 are merely examples, and the present disclosure is not limited thereto. Also, "weld bead A" shown in FIG. 5 corresponds to weld bead BD1 shown in FIG. 4. "weld bead B" shown in FIG. 5 corresponds to weld bead BD2 shown in FIG. 4. "weld bead C" shown in FIG. 5 corresponds to weld bead BD3 shown in FIG. 4.

[0095] The robot origin shown in FIG. 4 indicates the reference position of the welding robot MC1 in the reference posture.

[0096] When creating the appearance inspection program, inspection control device 3 scans each of three weld beads BD1, BD2, and BD3 created on workpiece Wk by main welding using sensor 4. The three weld beads BD1 to BD3 shown in FIG. 4 represent the position and shape of each weld bead recognized by inspection control device 3 based on point cloud data acquired by scanning with sensor 4. Based on the position and shape of each weld bead, inspection control device 3 acquires the inspection start position and inspection end position for when each of weld beads BD1 to BD3 is inspected by sensor 4.

[0097] Here, the inspection start position and the inspection end position are each determined to be a position in the welding direction that includes the actual weld bead acquired based on the point cloud data. Note that the inspection start position and the inspection end position may also be determined to be a position that is moved outside the weld bead by a predetermined offset amount from both ends of the weld bead in the welding direction. This allows the inspection control device 3 to scan each weld bead using the appearance inspection program, even if there are individual differences between the original workpieces or weld beads.

[0098] For example, inspection control device 3 <before change> performs visual inspection of weld bead BD1, weld bead BD2, and weld bead BD3 in the order corresponding to the welding order of the welding locations in the main welding. Based on the inspection order of weld beads BD1 to BD3, inspection control device 3 generates movement paths for moving sensor 4 in the order of movement path RT11, movement path RT12, movement path RT13, movement path RT14, movement path RT15, ​​movement path RT16, and movement path RT17. The direction of the arrow on each of movement paths RT11 to RT17 indicates the movement direction of sensor 4.

[0099] Here, movement path RT11 is a path for movement from the robot origin of welding robot MC1 to the inspection start point of weld bead BD1. Movement path RT12 is a path for movement from the inspection start point of weld bead BD1 to the inspection end point. Movement path RT13 is a path for movement from the inspection end point of weld bead BD1 to the inspection start point of the next weld bead BD2. Movement path RT14 is a path for movement from the inspection start point of weld bead BD2 to the inspection end point. Movement path RT15 is a path for movement from the inspection end point of weld bead BD2 to the inspection start point of the next weld bead BD3. Movement path RT16 is a path for movement from the inspection start point of weld bead BD3 to the inspection end point. Movement path RT13 is a path for movement from the inspection end point of weld bead BD3 to the robot origin of welding robot MC1.

[0100] The time chart <before change> shown in Fig. 5 is a time chart for the entire visual inspection when the visual inspection of the workpiece Wk is performed using the inspection order and movement path <before change> shown in Fig. 4. The processing time for the entire visual inspection <before change> is processing time T31.

[0101] On the other hand, the inspection control device 3 in this embodiment comprehensively optimizes the movement of sensor 4 and scanning by sensor 4 (i.e., the time required to control welding robot MC1), which is the visual inspection process of each weld bead, and the inspection time of the weld beads based on the scanned point cloud data (i.e., the time required for inspection processing by inspection control device 3), regardless of the inspection order corresponding to the welding order of the weld points in the main welding. In this way, the inspection control device 3 determines the inspection order and movement path to shorten the waiting time shown in the time chart <Before change> and further shorten the processing time of the entire visual inspection process of the workpiece Wk (i.e., optimize the visual inspection).

[0102] 4, inspection control device 3 generates an inspection order and movement path <after the change> by streamlining or optimizing the visual inspection of workpiece Wk based on the inspection order and movement path <before the change>. In the <after the change> state, inspection control device 3 determines the inspection order to be weld bead BD1, weld bead BD3, and weld bead BD2 in this order in order to optimize the movement time of sensor 4 when performing the visual inspection of three weld beads BD1 to BD3.

[0103] When performing visual inspection of the determined weld bead BD1, weld bead BD3, and weld bead BD2 in this order, inspection control device 3 generates movement paths for moving sensor 4 in the following order: movement path RT11, movement path RT12, movement path RT13A, movement path RT14A, movement path RT15A, movement path RT16A, and movement path RT17A. The direction of the arrow on each of movement paths Rt11 to RT12 and RT13A to RT17A indicates the movement direction of sensor 4.

[0104] Here, movement path RT13A is a path for movement from the inspection end point of weld bead BD1 to the inspection start point of the next weld bead BD3. Movement path RT14A is a path for movement from the inspection start point to the inspection end point of weld bead BD3. Movement path RT15A is a path for movement from the inspection end point of weld bead BD3 to the inspection start point of the next weld bead BD2. Movement path RT16A is a path for movement from the inspection start point to the inspection end point of weld bead BD2. Movement path RT17A is a path for movement from the inspection end point of weld bead BD2 to the robot origin of welding robot MC1.

[0105] The time chart <after change> shown in Figure 5 is a time chart for the entire visual inspection when visual inspection of the workpiece Wk is performed using the inspection order and movement path <after change> shown in Figure 4. The processing time for the entire visual inspection <after change> is processing time T41. By improving the efficiency or optimizing the entire visual inspection, the inspection control device 3 reduces the processing time required for the entire visual inspection by a reduction time T42 between <before change> and <after change>.

[0106] As described above, the inspection control device 3 not only simply minimizes the travel distance and travel time of the sensor 4, but also streamlines and optimizes the visual inspection, including the inspection time for each weld bead. This makes it possible to streamline and optimize the entire process performed by the inspection control device 3 and welding robot MC1, which perform the visual inspection of the workpiece Wk.

[0107] 4 and 5, weld bead BD2 (i.e., "weld bead B") is shown as having the longest bead length and the shortest inspection time, but this is not an error. In actual appearance inspections, the inspection time for a weld bead may not be proportional to the bead length, i.e., the amount of point cloud data obtained by sensor 4. For example, the inspection time for a weld bead may be short if the point cloud data obtained by sensor 4 is close to point cloud data indicating a non-defective product, or conversely, the inspection time may be long.

[0108] (Example 2 of Determining the Inspection Order and Movement Paths of Weld Beads) Next, Example 2 of Determining the Inspection Order and Movement Paths of a Plurality of Weld Beads will be described with reference to FIGS. 6 to 8. FIG.

[0109] 6 to 8 are diagrams showing a second example of determining the examination order and the movement route.

[0110] In Example 2 of determining the inspection order and movement paths of a plurality of weld beads shown in FIGS. 6 to 8, an example of generating an inspection order and movement paths when an obstacle OB exists on the generated movement path will be described.

[0111] The inspection order and movement routes shown in Fig. 6 are inspection order and movement routes determined by a conventional method, without improving or optimizing the efficiency of the overall visual inspection. The inspection order and movement routes shown in Fig. 7 are inspection order and movement routes determined by improving or optimizing the efficiency of the overall visual inspection in this embodiment. The inspection order and movement routes shown in Fig. 8 are inspection order and movement routes regenerated by discarding the inspection order and movement routes shown in Fig. 7.

[0112] In the example shown in FIGS. 6 to 8, the inspection control device 3 determines the inspection order of four weld beads BD1, BD2, BD3, and BD4 formed on the workpiece Wk and generates a movement path for the sensor 4.

[0113] The inspection order and movement paths shown in Figure 6 are generated and determined by a conventional method. In the inspection order and movement paths shown in Figure 6, the inspection order is determined to be in the order of weld bead BD1, weld bead BD2, weld bead BD3, and weld bead BD4, and movement paths are generated to move sensor 4 in the following order: movement path RT21, movement path RT22, movement path RT23, movement path RT24, movement path RT25, movement path RT26, movement path RT27, movement path RT28, and movement path RT29. The direction of the arrow on each of the movement paths RT21 to RT29 indicates the movement direction of sensor 4.

[0114] Based on the generated movement paths RT21 to RT29 and information on the obstacle OB corresponding to this work Wk, the inspection control device 3 determines whether or not the sensor 4 will interfere with or collide with the obstacle OB when the welding robot MC1 moves the sensor 4 along the movement paths RT21 to RT29.

[0115] The inspection order and movement paths shown in Fig. 7 are generated and determined by inspection control device 3 in this embodiment. In the example shown in Fig. 7, inspection control device 3 determines the inspection order in the following order: weld bead BD1, weld bead BD3, weld bead BD4, and weld bead BD2, and generates movement paths for moving sensor 4 in the following order: movement path RT21, movement path RT22, movement path RT23A, movement path RT24A, movement path RT25A, movement path RT26A, movement path RT27A, movement path RT28A, and movement path RT29A. The direction of the arrows on each of the movement paths RT21 to RT22 and RT23A to RT29A indicates the movement direction of sensor 4.

[0116] Based on the generated movement paths RT21-RT22, RT23A-RT29A and information on the obstacle OB corresponding to this workpiece Wk, the inspection control device 3 determines whether the sensor 4 will interfere with or collide with the obstacle OB when the welding robot MC1 moves the sensor 4 along the movement paths RT21-RT22, RT23A-RT29A. In the example shown in Figure 7, the inspection control device 3 determines that the sensor 4 will interfere with the obstacle OB at position Pt20 during movement along the movement path RT23A.

[0117] The inspection control device 3 generates avoidance routes RT231A and RT232A for the movement route RT23A that avoid interference between the sensor 4 and the obstacle OB. The inspection control device 3 calculates the overall processing time for the visual inspection when a movement route including the avoidance routes RT231A and RT232A is adopted instead of the movement route RT23A. If the calculated overall processing time for the visual inspection is longer than the overall processing time for the visual inspection performed using another inspection order and movement route, the inspection control device 3 regenerates another inspection order and movement route. On the other hand, if the calculated overall processing time for the visual inspection is shorter than the overall processing time for the visual inspection performed using another inspection order and movement route, the inspection control device 3 determines the movement route for the sensor 4 to be the movement route including the generated avoidance routes RT231A and RT232A.

[0118] Here, the inspection control device 3 will be described as taking a case where the calculated processing time for the entire visual inspection is longer than the processing time for the entire visual inspection performed in another inspection order and movement path.

[0119] If the calculated processing time for the entire visual inspection is longer than the processing time for the entire visual inspection performed using another inspection order and movement path, the inspection control device 3 generates and determines another inspection order and movement path shown in Figure 8.

[0120] The inspection order and movement paths shown in Figure 8 are generated and determined by inspection control device 3 in this embodiment. In the example shown in Figure 8, inspection control device 3 determines the inspection order in the following order: weld bead BD1, weld bead BD4, weld bead BD3, and weld bead BD2, and generates movement paths for moving sensor 4 in the following order: movement path RT21, movement path RT22, movement path RT23B, movement path RT24B, movement path RT25B, movement path RT26B, movement path RT27B, movement path RT28A, and movement path RT29A. The direction of the arrows on each of the movement paths RT21 to RT22, RT23B to RT27B, and RT28A to RT29A indicates the movement direction of sensor 4.

[0121] Based on the generated movement paths RT21-RT22, RT23B-RT27B, and RT28A-RT29A and information on the obstacle OB corresponding to this workpiece Wk, the inspection control device 3 determines whether or not the sensor 4 will interfere with or collide with the obstacle OB when the welding robot MC1 moves the sensor 4 along the movement paths RT21-RT22, RT23B-RT27B, and RT28A-RT29A. In the example shown in Figure 8, if the inspection control device 3 determines that the sensor 4 will not interfere with the obstacle OB during movement along the movement paths RT21-RT22, RT23B-RT27B, and RT28A-RT29A, it creates an appearance inspection program based on the inspection order and movement paths shown in Figure 8 and outputs it to the robot control device 2.

[0122] As described above, the inspection control device 3 in this embodiment can create a visual inspection program that streamlines or optimizes the overall processing time for the visual inspection while avoiding interference between the sensor 4 and the production equipment on which the workpiece Wk is produced (e.g., a jig or a support table for the workpiece Wk, etc.). Furthermore, when generating and determining an inspection order and movement path that avoids interference between the sensor 4 and the production equipment on which the workpiece Wk is produced, the inspection control device 3 determines whether to avoid the obstacle OB or generate a different inspection order or movement path based on the length of the overall processing time for the visual inspection. This allows for more efficient visual inspection of the weld beads of workpieces produced by main welding.

[0123] Although the embodiment of the present disclosure has been described above, the method of creating a visual inspection program in the present disclosure is not limited to this embodiment. For example, in the above-described embodiment, an example was described in which the inspection time and travel time were estimated for each of a plurality of weld beads and the inspection order of each weld bead was determined in order to shorten the overall processing time for the visual inspection. However, the plurality of weld beads formed on the workpiece Wk may be arbitrarily grouped in advance by the operator. The grouping of weld beads will be described with reference to FIG. 9 .

[0124] FIG. 9 is a diagram illustrating an example of grouping a plurality of weld beads according to a modified example of the embodiment of the present disclosure.

[0125] 9 , eight weld beads are produced on the workpiece Wk by main welding, and the eight weld beads are grouped into three groups Gr1, Gr2, and Gr3. The first group Gr1 includes weld beads BD11, BD12, and BD13. The second group Gr2 includes weld beads BD21, BD22, and BD23. The third group Gr3 includes weld beads BD31 and BD32.

[0126] A method for creating an appearance inspection program when a plurality of weld beads are grouped in this way will be described with reference to the flowchart shown in FIG.

[0127] First, the inspection control device 3 repeatedly executes the processes of steps St11 to St13 shown in FIG. 3 , determining the inspection start position and the inspection end position for all weld beads and scanning the weld beads, and then executes the processes of steps St15 to St17. In steps St18 and St19, the inspection control device 3 estimates the inspection time and movement time for one or more weld beads included in each group for each group. Based on the estimation results, the inspection control device 3 executes an optimization process for the inspection order of the first to Nth groups (N: an integer of 2 or greater) and the movement paths between the groups to determine the inspection order of the first to Nth groups. Furthermore, in steps St18 and St19, the inspection control device 3 executes an optimization process for the inspection order and movement paths RT31 to RT34 for one or more weld beads grouped in each group to determine the inspection order of the multiple weld beads and the movement paths within the group for each group.

[0128] By grouping in this manner, when there are a large number of weld beads to be inspected, the inspection control device 3 can execute the processing of step St18 (see Figure 3) in a shorter time by determining the inspection order for each group rather than determining the inspection order for each of multiple weld beads.

[0129] After determining the inspection order of each group and optimization processing of the movement paths between groups, and the inspection order of the multiple weld beads grouped in each group and optimization processing of the movement paths within the group, the inspection control device 3 executes the processing of steps St20 to St23. This enables the inspection control device 3 to further optimize the inspection order of the multiple weld beads within a group and the movement paths within the group based on the inspection order, thereby further shortening the overall processing time for the visual inspection even when a large number of weld beads are formed.

[0130] (Additional Notes) The above description of each embodiment discloses the following techniques.

[0131] (Technology 1) An appearance inspection program creation system comprising: a sensor 4 that scans multiple weld beads of a workpiece Wk produced by welding; and an inspection control device 3 that is capable of communicating with the sensor 4, wherein the inspection control device 3 is configured to: acquire input data (point cloud data) regarding the multiple weld beads; estimate the processing time for each of multiple processes (movement process, scanning process, inspection process, etc.) included in the appearance inspection of the multiple weld beads based on the input data; determine the inspection order of the multiple weld beads and the movement path of the sensor 4 based on the estimated processing time for each of the multiple processes; and create and output an appearance inspection program that causes a robot (welding robot MC1) that drives the sensor 4 to perform the appearance inspection of the multiple weld beads based on the determined inspection order of the multiple weld beads and the movement path of the sensor 4.

[0132] As a result, the inspection control device 3 can create an appearance inspection program that reduces the time (processing time) required to perform the entire appearance inspection and performs the appearance inspection of the workpiece more efficiently.

[0133] (Technology 2) The visual inspection program creation system described in (Technology 1), wherein the inspection control device 3 is configured to determine the inspection order of the plurality of weld beads and the movement path of the sensor 4 based on the processing time of each of the plurality of processes so as to minimize the overall time required for the visual inspection of the plurality of weld beads.

[0134] As a result, the inspection control device 3 can create an appearance inspection program that reduces the time (processing time) required to perform the entire appearance inspection and performs the appearance inspection of the workpiece more efficiently.

[0135] (Technology 3) The visual inspection program creation system described in (Technology 1) or (Technology 2), wherein the inspection control device 3 is configured to acquire information about the production equipment where the workpiece Wk is produced, and create and output the visual inspection program when it is determined that the sensor 4 moving along the movement path of the sensor 4 will not interfere with the production equipment based on the determined movement path of the sensor 4 and the information about the production equipment.

[0136] This allows the inspection control device 3 to create an appearance inspection program that does not interfere with production equipment and that performs appearance inspection of workpieces more efficiently.

[0137] (Technology 4) The visual inspection program creation system described in (Technology 3) is configured such that, when it is determined that the sensor 4 moving along the movement path of the sensor 4 will interfere with the production equipment, the inspection control device 3 determines an avoidance path that avoids interference between the sensor 4 and the production equipment, and creates and outputs the visual inspection program based on the inspection order of the multiple weld beads and the movement path of the sensor 4 that includes the determined avoidance path.

[0138] This allows the inspection control device 3 to create an appearance inspection program that does not interfere with production equipment and that performs appearance inspection of workpieces more efficiently.

[0139] (Technology 5) The visual inspection program creation system described in (Technology 3), wherein the inspection control device 3 is configured to: determine a new movement path for the sensor 4 when it is determined that the sensor 4 moving along the movement path of the sensor 4 will interfere with the production equipment; and create and output the visual inspection program based on the inspection order of the multiple weld beads and the determined new movement path of the sensor 4.

[0140] This allows the inspection control device 3 to create an appearance inspection program that does not interfere with production equipment and that performs appearance inspection of workpieces more efficiently.

[0141] (Technology 6) The visual inspection program creation system described in (Technology 3), wherein the inspection control device 3 is configured to: determine a new inspection order for the weld beads and a new movement path for the sensor 4 when it is determined that the sensor 4 moving along the movement path of the sensor 4 will interfere with the production equipment; and create and output the visual inspection program based on the new inspection order for the weld beads and the new movement path of the sensor 4.

[0142] This allows the inspection control device 3 to create an appearance inspection program that does not interfere with production equipment and that performs appearance inspection of workpieces more efficiently.

[0143] (Technology 7) The visual inspection program creation system described in any one of (Technology 1) to (Technology 6), wherein the inspection control device 3 is configured to estimate the processing time of each of the different processes for each of the multiple weld beads, and determine the inspection order of the multiple weld beads and the movement path of the sensor 4 based on the processing time of each of the multiple processes estimated for each of the multiple weld beads.

[0144] This allows the inspection control device 3 to create an appearance inspection program that adjusts the efficiency of the overall appearance inspection of the workpiece Wk on a weld bead basis.

[0145] (Technology 8) The visual inspection program creation system described in any one of (Technology 1) to (Technology 7), wherein the inspection control device 3 is configured to: acquire information on a plurality of groups into which the plurality of weld beads are grouped; estimate the processing time for each of the plurality of processes for each of the plurality of groups; determine an inspection order for the plurality of groups and a movement path for the sensor 4 between groups based on the estimated processing time for each of the plurality of processes for each of the plurality of groups; and determine an inspection order for one or more weld beads included in the plurality of groups and a movement path for the sensor within the group for each of the plurality of groups.

[0146] As a result, when the number of weld beads on the workpiece Wk is large, the inspection control device 3 can reduce the number of parameters (i.e., weld beads) used to improve the efficiency of the overall visual inspection by grouping them, compared to when determining the inspection order and movement path on a weld bead-by-weld bead basis.This reduces the time required for the process to improve the efficiency of the overall visual inspection, and makes it possible to create an actual visual inspection program that further improves the efficiency of the overall visual inspection.

[0147] (Technology 9) The visual inspection program creation system described in any one of (Technology 1) to (Technology 6), wherein the inspection control device 3 is configured to: create an inspection program for performing the visual inspection of the plurality of weld beads based on the input data; decompose the created inspection program into each of the plurality of weld beads and estimate the processing time of each of the plurality of processes included in the visual inspection for each of the plurality of weld beads; and determine the inspection order of the plurality of weld beads and the movement path of the sensor 4 based on the estimated processing time of each of the plurality of processes for each of the plurality of weld beads.

[0148] This allows the inspection control device 3 to create an appearance inspection program that allows for more efficient appearance inspection of the workpiece.

[0149] (Technology 10) An appearance inspection program creation system according to any one of (Technology 1) to (Technology 7), wherein the plurality of processes are a movement process in which the sensor 4 moves so as to be able to scan each of the plurality of weld beads, a scanning process in which the sensor 4 scans each of the plurality of weld beads, and an inspection process in which an appearance inspection is performed on each of the plurality of weld beads scanned by the sensor 4.

[0150] As a result, the inspection control device 3 not only simply minimizes the travel distance or travel time of the sensor 4, but also streamlines or optimizes the visual inspection, including the inspection time of each weld bead, thereby making it possible to streamline or optimize the entire process performed by the inspection control device 3 and welding robot MC1, which perform the visual inspection of the workpiece Wk.

[0151] (Technology 11) An appearance inspection program creation device (inspection control device 3) comprising: an acquisition unit (shape detection control unit 34) that acquires input data (point cloud data) regarding multiple weld beads of a workpiece Wk produced by welding; a determination unit (appearance inspection program creation unit 36) that estimates, based on the input data, the processing time for each of multiple processes (movement process, scanning process, inspection process, etc.) included in the appearance inspection of the multiple weld beads, and determines, based on the estimated processing time for each of the multiple processes, a combination of an inspection order for the multiple weld beads and a movement path of a sensor 4 that scans the multiple weld beads; and an output unit (appearance inspection program creation unit 36) that creates and outputs, based on the determined inspection order for the multiple weld beads and the movement path of the sensor 4, an appearance inspection program that causes a robot (welding robot MC1) that drives the sensor 4 to perform the appearance inspection of the multiple weld beads.

[0152] As a result, the inspection control device 3 can create an appearance inspection program that reduces the time (processing time) required to perform the entire appearance inspection and performs the appearance inspection of the workpiece more efficiently.

[0153] (Technology 12) A method for creating an appearance inspection program performed by a processor 31, comprising: accepting input data (point cloud data) regarding multiple weld beads of a workpiece Wk produced by welding; estimating, based on the input data, the processing time for each of multiple processes (movement process, scanning process, inspection process, etc.) included in the appearance inspection of the multiple weld beads; determining, based on the estimated processing time for each of the multiple processes, an inspection order for the multiple weld beads and a movement path for a sensor 4 that scans the multiple weld beads; and creating and outputting, based on the determined inspection order for the multiple weld beads and the movement path for the sensor 4, an appearance inspection program that causes a robot (welding robot MC1) that drives the sensor 4 to perform the appearance inspection of the multiple weld beads.

[0154] This allows the processor 31 of the inspection control device 3 to create an appearance inspection program that reduces the time (processing time) required to perform the entire appearance inspection and performs the appearance inspection of the workpiece more efficiently.

[0155] (Technology 13) A program for creating an appearance inspection program executed by a processor 31, the program causing the processor to execute the following steps: accepting input data (point cloud data) regarding multiple weld beads of a workpiece Wk produced by welding; estimating, based on the input data, the processing time for each of multiple processes (movement process, scanning process, inspection process, etc.) included in the appearance inspection of the multiple weld beads; determining, based on the estimated processing time for each of the multiple processes, the inspection order of the multiple weld beads and the movement path of a sensor 4 that scans the multiple weld beads; and creating and outputting, based on the determined inspection order of the multiple weld beads and the movement path of the sensor 4, an appearance inspection program that causes a robot (welding robot MC1) that drives the sensor 4 to perform the appearance inspection of the multiple weld beads.

[0156] As a result, the processor 31 of the inspection control device 3 that executes the visual inspection program creation program can create a visual inspection program that reduces the time (processing time) required to perform the entire visual inspection and performs visual inspection of the work more efficiently.

[0157] Although various embodiments have been described above with reference to the drawings, it goes without saying that the present disclosure is not limited to such examples. It is clear that a person skilled in the art can conceive of various modifications, alterations, substitutions, additions, deletions, and equivalents within the scope of the claims, and it is understood that these also naturally fall within the technical scope of the present disclosure. Furthermore, the components of the various embodiments described above may be combined in any manner without departing from the spirit of the present disclosure.

[0158] The present disclosure is useful as an appearance inspection program creation system, an appearance inspection program creation device, an appearance inspection program creation method, and an appearance inspection program creation program that create an appearance inspection program that more efficiently performs appearance inspection of weld beads on workpieces produced by this welding.

[0159] REFERENCE SIGNS LIST 1 Upper device 2 Robot control device 3 Inspection control device 4 Sensor 10, 20, 30 Communication unit 11, 21, 31 Processor 12, 22, 32 Memory 13 Cell control unit 23 Actual welding program creation unit 24 Calculation unit 25 Robot control unit 26 Power supply control unit 33 Inspection result storage unit 34 Shape detection control unit 35 Data processing unit 36 ​​Visual inspection program creation unit 100 Welding system 200 Manipulator 300 Wire feeder 301 Welding wire 400 Welding torch 500 Power supply unit BD1 to BD4, BD11 to BD31 Weld bead Gr1, Gr2, Gr3 Group MC1 Welding robot MN1, MN2 Monitor OB Obstacle P1 Terminal device Pt20 Position RT12 to RT17, RT21 to RT29, RT13A to RT17A, RT23A to RT29A, RT23B to RT27B, RT31 to RT34 Movement route RT231A, RT232A Avoidance route ST External storage St11 to St23 Step T11, T21, T31, T41 Processing time T22, T42 Reduced time UI1 Input interface Wk Work

Claims

1. A visual inspection program creation system comprising: a sensor that scans multiple weld beads of a workpiece produced by welding; and an inspection control device capable of communicating with the sensor, wherein the inspection control device is configured to: acquire input data regarding the multiple weld beads; estimate, based on the input data, the processing time for each of multiple processes included in the visual inspection of the multiple weld beads; determine an inspection order for the multiple weld beads and a movement path for the sensor based on the estimated processing time for each of the multiple processes; and create and output a visual inspection program that causes a robot that drives the sensor to perform the visual inspection of the multiple weld beads based on the determined inspection order for the multiple weld beads and the movement path for the sensor.

2. The visual inspection program creation system of claim 1, wherein the inspection control device is configured to determine the inspection order of the multiple weld beads and the movement path of the sensor based on the processing time of each of the multiple processes so as to minimize the overall time required for the visual inspection of the multiple weld beads.

3. The visual inspection program creation system of claim 1, wherein the inspection control device is configured to acquire information about the production equipment where the work is produced, and create and output the visual inspection program when it determines, based on the determined movement path of the sensor and the information about the production equipment, that the sensor moving along the movement path of the sensor will not interfere with the production equipment.

4. The visual inspection program creation system of claim 3, wherein the inspection control device is configured to: determine an avoidance path to avoid interference between the sensor and the production equipment when it is determined that the sensor moving along the sensor's movement path will interfere with the production equipment; and create and output the visual inspection program based on the inspection order of the multiple weld beads and the sensor's movement path including the determined avoidance path.

5. The visual inspection program creation system of claim 3, wherein the inspection control device is configured to: determine a new movement path for the sensor when it is determined that the sensor moving along the movement path will interfere with the production equipment; and create and output the visual inspection program based on the inspection order of the multiple weld beads and the determined new movement path for the sensor.

6. The visual inspection program creation system of claim 3, wherein the inspection control device is configured to: determine a new inspection order for the weld beads and a new movement path for the sensor when it is determined that the sensor moving along the movement path of the sensor will interfere with the production equipment; and create and output the visual inspection program based on the new inspection order for the weld beads and the new movement path of the sensor.

7. The visual inspection program creation system of claim 1, wherein the inspection control device is configured to estimate the processing time for each of the different processes for each of the weld beads, and determine the inspection order of the weld beads and the movement path of the sensor based on the processing time for each of the different processes estimated for each of the weld beads.

8. The visual inspection program creation system of claim 1, wherein the inspection control device is configured to: acquire information on a plurality of groups into which the plurality of weld beads are grouped; estimate the processing time for each of the plurality of processes for each of the plurality of groups; determine the inspection order of the plurality of groups and the movement path of the sensor between groups based on the estimated processing time for each of the plurality of processes for each of the plurality of groups; and determine the inspection order of one or more weld beads included in the plurality of groups and the movement path of the sensor within the group for each of the plurality of groups.

9. The visual inspection program creation system of claim 1, wherein the inspection control device is configured to: create an inspection program for performing the visual inspection of the plurality of weld beads based on the input data; decompose the created inspection program into each of the plurality of weld beads and estimate the processing time of each of the plurality of processes included in the visual inspection for each of the plurality of weld beads; and determine the inspection order of the plurality of weld beads and the movement path of the sensor based on the estimated processing time of each of the plurality of processes for each of the plurality of weld beads.

10. The visual inspection program creation system of claim 1, wherein the plurality of processes are a movement process in which the sensor moves so as to be able to scan each of the plurality of weld beads, a scanning process in which the sensor scans each of the plurality of weld beads, and an inspection process in which an appearance inspection is performed on each of the plurality of weld beads scanned by the sensor.

11. An appearance inspection program creation device comprising: an acquisition unit that acquires input data regarding a plurality of weld beads of a workpiece produced by welding; a determination unit that estimates, based on the input data, the processing time for each of a plurality of processes included in the appearance inspection of the plurality of weld beads, and determines, based on the estimated processing time for each of the plurality of processes, a combination of an inspection order for the plurality of weld beads and a movement path of a sensor that scans the plurality of weld beads; and an output unit that creates and outputs, based on the determined inspection order for the plurality of weld beads and the movement path of the sensor, an appearance inspection program that causes a robot that drives the sensor to perform the appearance inspection of the plurality of weld beads.

12. A visual inspection program creation method performed by a processor, comprising: accepting input data relating to multiple weld beads of a workpiece produced by welding; estimating the processing time for each of multiple processes included in the visual inspection of the multiple weld beads based on the input data; determining the inspection order of the multiple weld beads and the movement path of a sensor that scans the multiple weld beads based on the estimated processing time for each of the multiple processes; and creating and outputting a visual inspection program that causes a robot that drives the sensor to perform the visual inspection of the multiple weld beads based on the determined inspection order of the multiple weld beads and the movement path of the sensor.

13. A program for creating an appearance inspection program executed by a processor, the program causing the processor to execute the following steps: accepting input data relating to multiple weld beads of a workpiece produced by welding; estimating, based on the input data, the processing time for each of multiple processes included in the appearance inspection of the multiple weld beads; determining, based on the estimated processing time for each of the multiple processes, an inspection order for the multiple weld beads and a movement path for a sensor that scans the multiple weld beads; and creating and outputting, based on the determined inspection order for the multiple weld beads and the movement path for the sensor, an appearance inspection program that causes a robot that drives the sensor to perform the appearance inspection of the multiple weld beads.

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