Assistance system, control method, and assistance program

Abstract

In this assistance system, which comprises a computer and assists in setting welding conditions for an article, the computer receives model data of the article from a client terminal, and identifies from the model data a spot welding position where spot welding is to be performed.

Description

Support System, Control Method, and Support Program

[0001] The present invention relates to a support system, a control method, and a support program for assisting in setting welding conditions for an article.

[0002] Patent Document 1 discloses a method for creating an estimate for sheet metal processing work. In this creation method, three-dimensional CAD data in which a product is modeled in three-dimensional CAD is received from an orderer. Then, referring to the three-dimensional perspective view, the product is divided into a plurality of parts. Also, a developed view is created for each of the parts divided into a plurality. Further, when calculating the welding cost, the three-dimensional perspective view divided into a plurality of parts is read, the welding surface is indicated, and the welding length is calculated.

[0003] Patent Document 2 discloses a sheet metal equipment sales system. In this system, design data such as CAD drawings is received and a three-dimensional perspective view is created. Then, the three-dimensional perspective view is divided into three-dimensional perspective views of parts, and a developed view is created by referring to the three-dimensional perspective views of the parts. Further, it is determined whether the parts of the product can be processed, and when it is determined that all parts can be processed, the welding locations are extracted and the processing method is examined.

[0004] Patent Document 3 discloses a robot system including a welding robot. In this system, a welding line for performing welding with the welding robot is automatically selected based on the work shape of the three-dimensional CAD data displayed on the display screen.

[0005] Japanese Unexamined Patent Application Publication No. 2002-203007, Japanese Unexamined Patent Application Publication No. 2005-157820, Japanese Unexamined Patent Application Publication No. 2010-184278

[0006] For an article that a user desires to manufacture, welding may be performed. In this case, the price of the article varies depending on the welding method. For example, spot welding performed using a spot welding machine is cheaper for the processed article than seam welding that welds linearly continuously or intermittently. Therefore, when a user desires spot welding, means for automatically specifying the position where spot welding is to be performed is required.

[0007] A support system according to one embodiment is a support system equipped with a computer that assists in setting welding conditions for an article, wherein the computer receives model data of the article from a client terminal and identifies spot welding locations to be spot welded from the model data.

[0008] Another control method according to a different embodiment is a control method for a support system equipped with a computer that assists in setting welding conditions for an article, wherein the computer receives model data of the article from a client terminal and identifies spot welding positions to be performed from the model data.

[0009] Another support program according to a different embodiment is a support program for a support system equipped with a computer that assists in setting welding conditions for an article, wherein the computer receives model data of the article from a client terminal and identifies spot welding locations to be performed from the model data.

[0010] A schematic diagram of the entire support system. A schematic block diagram of the support system's control system. A schematic diagram showing an example of a three-dimensional object. An explanatory diagram to show an increase or decrease in the number of spot welding positions. A schematic diagram showing another example of a three-dimensional object. A flowchart of the support process.

[0011] Hereinafter, exemplary embodiments for carrying out the present invention will be described in detail with reference to the drawings. However, the dimensions, materials, shapes, and relative positions of components described in the following embodiments can be arbitrarily set and modified according to the configuration of the apparatus or method to which the present invention is applied, or according to various conditions. Furthermore, unless otherwise specified, the scope of the present invention is not limited to the embodiments specifically described below.

[0012] In the following description, identification information is data consisting of letters, numbers, symbols, images, or combinations thereof, and uniquely identifies the object to be identified linked to the identification information. Furthermore, a model of an article or part is a 3D model displayed based on three-dimensional CAD data, or a 2D model displayed based on two-dimensional CAD data. In the model, the article and the parts that make up the article may be a single entity, the parts that make up the article may be separate from the article, or the article may contain multiple parts.

[0013] [Embodiment] Figure 1 shows a support system 100 that assists in setting welding conditions for an article. For example, the user uploads model data D1 (Figure 2) of the article from a client terminal 40. The server 20 of the support system 100 receives and stores the model data D1 from the client terminal 40. Furthermore, the server 20 assists in setting the positions for spot welding as welding conditions. The article may be a finished product having a single unified function, a single article incorporated into a finished product, or an assembly consisting of multiple parts. Furthermore, the article may include units, jigs, devices, and equipment made up of multiple parts.

[0014] Model data D1 is, for example, three-dimensional CAD (Computer-Aided Design) data representing the shape of an article. This model data D1 may include information such as the dimensions and positions of the elements that make up the article. The elements are, for example, parts that make up the article such as holes, shafts, steps, notches, corners, faces, and edges, and include shapes obtained by processing. The welding conditions are at least the welding locations where spot welding will be performed. Furthermore, the welding conditions may include conditions such as the number of welding locations, welding length, welding machine to be used, welding method, and weld allowance. In the following description, an example of a welding condition that assists in setting the welding locations will be explained.

[0015] The support system 100 is configured as a network system or client-server system equipped with a server 20 as a support server. The server 20 functions as a server device and is configured as a single logical server device by combining, for example, multiple server units 21 as computers. However, the server 20 may be configured by a single server unit 21. Alternatively, the server 20 may be logically configured using cloud computing.

[0016] The server 20 provides various services to the client terminal 40, or to the user of the client terminal 40, including support services for setting welding conditions and material quotation services. These services include a distribution service that delivers programs or data to the client terminal 40 via the network 50, and a storage service that stores data received from the client terminal 40. The distribution service is, for example, a service that delivers update data.

[0017] The client terminal 40 is a computer device capable of network connectivity. For example, the client terminal 40 includes a stationary or book-type personal computer 41, and a portable tablet device 42, etc. In addition, mobile terminal devices such as smartphones and other mobile phones are also included in the client terminal 40. By implementing various computer software, the client terminal 40 can allow users to enjoy various services provided by the server 20. Furthermore, the client terminal 40 can connect to the server 20 via a predetermined network 50. Below, an example in which the client terminal 40 is a personal computer 41 will be described.

[0018] Network 50 is configured to allow client terminals 40 to connect to each server 20. For example, network 50 is configured to achieve network communication using the TCP / IP protocol. Specifically, a LAN (Local Area Network) 52 connects server 20 to the Internet 51. The Internet 51, which is a WAN (Wide Area Network), and LAN 52 are connected via a router 53. Network 50 may be a dedicated line, telephone line, corporate network, mobile communication network, other communication line, or a combination thereof, and may be wired or wireless. The client terminals 40 are also configured to connect to the Internet 51. Alternatively, the server units 21 of server 20 may be interconnected via the Internet 51 instead of or in addition to LAN 52.

[0019] The server 20 guides the user through the various procedures necessary for setting welding conditions for the items via the client terminal 40. For example, the server 20 functions as a web server that displays various web pages on the client terminal 40 in response to access from the client terminal 40. The server 20 may also perform processes such as arranging for ordered items, issuing delivery instructions, and billing for purchase price in response to orders placed by the user.

[0020] [Control System] Next, with reference to Figure 2, the schematic configuration of the control system of the support system 100 will be described. The server 20 includes a server control unit 22 as a control means and a server memory 23 as a computer-readable non-temporary storage medium. The server control unit 22 is configured as a computer that combines a processor that performs various calculations and operation controls according to a predetermined program, internal memory necessary for the operation of the processor, and other peripheral devices. The processor is, for example, a CPU (Central Processing Unit) or an MPU (Micro-Processing Unit), and controls the entire server and comprehensively controls various processes based on the control program stored in the server memory 23. Furthermore, the server control unit 22 performs various processes associated with setting welding conditions for articles based on the support program PG stored in the server memory 23.

[0021] The server memory 23 includes RAM (Random Access Memory), which is system work memory for the processor to operate, as well as storage devices such as ROM (Read Only Memory), HDD (Hard Disk Drive), and SSD (Solid State Drive) for storing programs and system software. However, the server memory 23 is not limited to being provided as part of the server 20, but may also be provided as a database server that cooperates with the server 20. The server memory 23 also stores the uploaded model data D1 and the generated welding pattern data D2. In the following description, the CPU performs various calculations, control, and discrimination operations according to the control program stored in the ROM or HDD.

[0022] The server control unit 22 is connected via wired or wireless connection to an operation unit (not shown) that includes a keyboard or various switches for inputting predetermined commands and data. The server control unit 22 is also connected via wired or wireless connection to a display unit (not shown) that displays the input status, setting status, measurement results, and various information of the server device. Furthermore, the server control unit 22 can also perform control according to programs stored on portable recording media such as CDs (Compact Discs), DVDs (Digital Versatile Discs), CF (Compact Flash) cards, and USB (Universal Serial Bus) memory, or external storage media such as cloud servers on the Internet.

[0023] The support program PG stored in the server memory 23 causes the server control unit 22, which is a computer, to function as an acceptance unit 22A (an example of an acceptance means), an identification unit 22B (an example of an identification means), a determination unit 22C (an example of a determination means), a generation unit 22E (an example of a generation means), a presentation unit 22F (an example of a presentation means), and an estimation unit 22G (an example of an estimation means). In other words, the server control unit 22, as a logical device realized by a combination of computer hardware and software, has an acceptance unit 22A, an identification unit 22B, a determination unit 22C, a generation unit 22E, a presentation unit 22F, and an estimation unit 22G.

[0024] In addition to the logical devices described above, the server control unit 22 also has other logical devices (not shown) that control the switching of web page displays in response to operations on the client terminal 40. Furthermore, the server memory 23 stores various types of data (not shown), including user information, past quotation results, images and layout data used to display web pages, and data containing information such as product or item model numbers, names, or characteristics.

[0025] [Receiving means] The receiving unit 22A receives the model data D1 of the article from the client terminal 40. For example, the user uploads the model data D1 to the server 20. The receiving unit 22A then stores the model data D1 received from the user's client terminal 40 in the server memory 23. Here, the article represented by the model data D1 includes at least two parts that are welded together. Each of the parts to be welded may be a separate component or part of a single component. For example, the parts to be welded may be formed by bending and overlapping parts of a single component. However, in the following, we will mainly describe an example where each of the two parts is a separate component.

[0026] [Specific Means] Next, the function of the specific part 22B will be explained with reference to Figure 3. Figure 3 shows a three-dimensional object 13 in plan view. The three-dimensional object 13 represents an article formed by welding a small plate-shaped part P1 and a large plate-shaped part P2. In Figure 3, of the four spot welding positions 11, only the spot welding position 11 in the lower left of Figure 3 is given a reference numeral, and the other reference numerals are omitted from the illustration.

[0027] The identification unit 22B identifies the spot welding locations 11 to be welded from the model data D1. This eliminates the need for the user to identify the spot welding locations 11, reducing the man-hours and time required for the design of the item. It also prevents the user from making the mistake of identifying the wrong spot welding locations 11. Specifically, before identifying the spot welding locations 11, the identification unit 22B identifies the welded areas in the model data D1. If it is possible to perform spot welding on the identified welded areas, the identification unit 22B identifies the spot welding locations 11 in those areas. The identification unit 22B also identifies multiple spot welding locations 11. However, if there is no problem with the strength of the welded area, there may be only one spot welding location 11. Also, there may be multiple welded areas on a single item.

[0028] As an example, the identification unit 22B performs shape recognition processing of an article based on the model data D1. In this shape recognition processing, the identification unit 22B recognizes the shape of each element based on the model data D1. Furthermore, the identification unit 22B recognizes each part that constitutes the article. Subsequently, the identification unit 22B creates pattern data having a topological structure. For example, the topological structure contains information on the connection relationships between parts, the adjacency relationships between parts, and the surface recognition of each part enclosed by lines. Then, the identification unit 22B identifies areas in the article where welding is possible. For example, the identification unit 22B identifies areas where the surfaces of multiple parts included in the article overlap as weldable areas. As a result, the identification unit 22B can identify weldable areas and spot welding positions 11 based on the model data D1.

[0029] In the example shown in Figure 3, the welded area is the portion where the surfaces of the two target parts to be welded overlap in the three-dimensional object 13. That is, the overlapping area where the small part P1 and the large part P2 overlap is the welded area, and the welded area is defined by the outline of the small part P1. In other words, the welded area is a rectangular portion having a lateral edge W1 and a vertical edge L1.

[0030] Furthermore, the specific unit 22B identifies a spot welding position 11 in the welded portion that satisfies predetermined specific conditions. Specifically, the specific unit 22B identifies a spot welding position 11 that satisfies at least one of the specific conditions described below. For example, the specific conditions are set in accordance with the Welding Engineering Standard established by the Japan Welding Society. As an example, the specific condition is that the position lies on an offset line 12 offset by a predetermined offset length E from the edge of the welded portion. For example, the offset length E is the length from the outline of the small part P1 corresponding to the edge of the welded portion to the spot welding position 11, and is a length calculated by multiplying a predetermined nugget diameter (mm) by a coefficient of 1.5, or any length longer than the length calculated in this way.

[0031] For example, the offset length E corresponding to the minimum edge distance according to the Japan Welding Society standard is 5.0 mm when both the small part P1 and the large part P2 are made of aluminum and have a plate thickness of 0.4 mm. The server memory 23 stores the predetermined distance and other conditions according to the Japan Welding Society standard for each material and plate thickness. Furthermore, if the plate thicknesses of multiple parts to be welded are different, specific conditions corresponding to the plate thickness of the thinnest part are applied. In Figure 3, the offset line 12 is shown as a dashed line, but the offset line 12 is not displayed on the client terminal 40. Alternatively, the offset line 12 may be displayed on the client terminal 40.

[0032] Furthermore, the specific condition may be that the number of spot welding positions 11 is minimized. In the example in Figure 3, the edge of the welded portion coincides with the outline of the small part P1. The specific section 22B identifies the positions of the four corners of the virtual rectangular area drawn by the offset line 12 as spot welding positions 11, which are located on the offset line 12 and have the fewest number of spot welding positions 11. In other words, the specific section 22B identifies the spot welding positions 11 such that there are at least two spot welding positions 11 on each side of the area defined by the offset line 12.

[0033] Furthermore, the specific condition may be that, when multiple spot welding positions 11 are specified, the welding pitch P between the multiple spot welding positions 11 is longer than a predetermined pitch. In the example in Figure 3, the specification part 22B specifies the spot welding positions 11 such that the welding pitch P at the edge L1 is longer than a predetermined pitch. For example, the predetermined pitch is a length calculated by multiplying the nugget diameter by a coefficient of 4.0, or any length longer than the length calculated in this way.

[0034] For example, the specified pitch according to the Japan Welding Society standards is 13.0 mm when both the small part P1 and the large part P2 are made of aluminum and have a plate thickness of 0.4 mm. The specified pitch is the distance between two adjacent spot welding positions 11. Therefore, the distance between two adjacent spot welding positions 11 that are vertically, horizontally, above, below, or diagonally adjacent is also taken into consideration. This ensures that the welding pitch P is long enough to prevent flow separation.

[0035] Alternatively, the specific condition may be that the number of spot welding positions 11 is maximized. For example, the specific unit 22B identifies multiple spot welding positions 11 such that the welding pitch P, which is the distance between the spot welding positions 11, is minimized. This allows for the identification of more spot welding positions 11. Or, the specific condition may be that the number of spot welding positions 11 is an intermediate number between the minimum and maximum numbers, or any predetermined number.

[0036] Furthermore, if it is impossible to perform spot welding on the welded portion, the identification unit 22B may, as an error handling measure, identify the linear welding position in the welded portion. This allows for the preferential suggestion of spot welding, and, if spot welding is impossible, the alternative linear welding can be suggested. In the example shown in Figure 3, the identification unit 22B identifies the boundary line between the small part P1 and the large part P2, along the outline of the small part P1, as the linear welding position. For example, if the determination unit 22C determines that spot welding is impossible, the identification unit 22B identifies the linear welding position in the welded portion. Note that the welded portion may contain a mixture of areas where spot welding is impossible and areas where spot welding is possible.

[0037] As an example, the specific part 22B identifies the linear welding position in the welded portion when the distance from the welded portion to the position corresponding to the end face of the article is less than a predetermined distance. The specific part 22B also identifies the linear welding position in the welded portion when the distance from the welded portion to the bending position is less than a predetermined distance. Furthermore, the specific part 22B identifies the linear welding position in the welded portion when the length of the welded portion is less than a predetermined length. Note that if the length of the welded portion is less than a predetermined length, the number of spot welding positions 11 is insufficient to meet the minimum number of welding locations, and therefore it is determined that spot welding is impossible.

[0038] Furthermore, if the identification unit 22B identifies multiple spot welding positions 11, the receiving unit 22A may accept an operation to increase or decrease the number of spot welding positions 11 from the client terminal 40. If an increase operation is accepted, the identification unit 22B shortens the welding pitch P between the multiple spot welding positions 11 and re-identifies the multiple spot welding positions 11 after changing the welding pitch P. On the other hand, if a decrease operation is accepted, the identification unit 22B lengthens the welding pitch P and re-identifies the multiple spot welding positions 11 after changing the welding pitch P.

[0039] Specifically, the increase or decrease in the number of spot welding positions 11 will be explained with reference to Figures 4A to 4C. Figure 4A shows the initial number of spot welding positions 11 automatically suggested to the user. Figure 4B shows the number of spot welding positions 11 corresponding to the increase operation. Figure 4C shows the number of spot welding positions 11 corresponding to the decrease operation. The pitch arrow A indicating the welding pitch P may or may not be displayed on the display device 46.

[0040] To increase the number of spot welding positions 11, the user performs an increase operation by selecting the increase button B. This automatically increases the number of spot welding positions 11, as shown in Figure 4B. For example, the number of multiple spot welding positions 11 proposed after the increase operation is the maximum number of positions that can be spot welded. Also, the number of multiple spot welding positions 11 initially proposed, as shown in Figure 4A, is an intermediate number between the maximum and minimum number of positions that can be spot welded. If there are multiple intermediate numbers between the maximum and minimum, the smaller number will be used as the initial number of spot welding positions 11.

[0041] For example, the maximum number of spot welding positions 11 is the number when the predetermined pitch indicated by specific conditions is set as the minimum pitch. In this case, the welding pitch P of the multiple spot welding positions 11 will be the minimum pitch. Also, the minimum number of spot welding positions 11 is the number when the predetermined pitch indicated by specific conditions is set as the maximum pitch. In this case, the welding pitch P of the multiple spot welding positions 11 will be the maximum pitch.

[0042] To reduce the number of spot welding positions 11, the user performs a reduction operation by selecting the reduction button C. As shown in Figure 4C, the number of spot welding positions 11 is automatically reduced. For example, the number of spot welding positions 11 suggested after the reduction operation is the minimum number of positions for which spot welding is possible. In this way, by accepting the specification of increasing or decreasing the number of spot welding positions 11, the number of spot welds can be applied according to the desired strength of the welded area. Furthermore, by changing the length of the welding pitch P in accordance with the increase or decrease in the number of spot welding positions 11, it is possible to prevent the welding pitch P from falling below the minimum pitch or exceeding the maximum pitch.

[0043] Further, the increase button B and the decrease button C may be displayed on the display device 46 according to a user operation. For example, an editing button for the welding position may be displayed on the display device 46, and when the user performs an operation of selecting the editing button, the increase button B and the decrease button C may be displayed. Alternatively, the increase operation may be an operation in which the user selects the pitch arrow A and drags it so that its length becomes shorter. Also, the decrease operation may be an operation in which the user selects the pitch arrow A and drags it so that its length becomes longer. Further, the increase operation and the decrease operation may be operations in which the user inputs the welding pitch P or the number of spot welding positions 11 into a predetermined input field.

[0044] When increasing or decreasing the number of spot welding positions 11 according to the input operation, the receiving part 22A may not accept an increase or decrease specification such that the welding pitch P is below the minimum pitch or above the maximum pitch. For example, the input field may be provided with an upper limit and a lower limit of the weld pitch P or the number of spot welding positions 11 that can be input. Alternatively, the receiving part 22A may present an error to the user when the welding pitch P is below the minimum pitch or above the maximum pitch as a result according to the user's specification. Also, when the increase or decrease specification is such that the welding pitch P is below the minimum pitch or above the maximum pitch, the presenting part 22F may change the display so that the specification cannot be made. For example, the reflection button that reflects the result input into the input field may be grayed out or made invisible. Also, instead of directly increasing or decreasing the number of spots, a pattern of the number of spots (that is, the number of spot welding positions 11) may be selectable. For example, the receiving part 22A may accept a user operation of selecting from the options "normal / many / few" of the spot number pattern displayed on the screen, and increase or decrease the number of spots according to the received selection. Also, when accepting the selection, the presenting part 22F may display a finished prediction image corresponding to the number of spots on the display device 46. In this case, the presenting part 22F may display a finished prediction image for each material of the parts on the display device 46.

[0045] [Determination Means] Next, the function of the determination unit 22C will be explained with reference to Figure 5. Figure 5 shows another example of a three-dimensional object 15 in plan view. The three-dimensional object 15 represents an article formed by welding a small plate-shaped part P3 and a large plate-shaped part P4. In Figure 5, of the five spot welding positions 11, only the leftmost spot welding position 11 in Figure 5 is given a reference numeral, and the other reference numerals are omitted from the illustration. Furthermore, in Figure 5, of the multiple welding pitches P, only the leftmost welding pitch P in Figure 5 is shown.

[0046] In the example shown in Figure 5, the welded area is the portion where the faces of two target parts to be welded overlap in the three-dimensional object 15. That is, the overlapping area where the small part P3 and the large part P4 overlap is the welded area, and the overlapping area 16 defined by a part of the outline of the small part P3 and a dashed line is the welded area. In other words, the welded area in Figure 5 is a virtual rectangular area having a horizontally extending edge W2 and a vertically extending edge L2.

[0047] The determination unit 22C determines whether or not spot welding is possible on the weld portion in the model data D1. Specifically, the determination unit 22C determines that spot welding is possible if the weld portion includes a position that satisfies a predetermined determination condition. The determination unit 22C also determines that spot welding is possible if the weld portion includes a position that satisfies at least one of the determination conditions described below. For example, one determination condition is that the distance from the weld portion to the position corresponding to the end face of the article is greater than or equal to a predetermined distance. For example, the comparison with the predetermined distance is made at the point where the distance from the weld portion to the position corresponding to the end face of the article is the longest. For example, the predetermined distance is 10.0 mm.

[0048] In the example of FIG. 5, the distance from one end face S4 of the large part P4 to the edge of the overlapping portion 16 is longer than the distance from one end face S3 of the small part P3 to the edge of the overlapping portion 16. Therefore, if the distance from the end face S4 of the large part P4 to the edge of the overlapping portion 16 is equal to or greater than a predetermined distance, the determination unit 22C determines that spot welding can be performed. The predetermined distance varies depending on the spot welding machine used for welding. That is, the predetermined distance is determined based on whether the welding portion can be sandwiched by the electrodes of the spot welding machine based on the distance from the end face of the article to the welding portion. Thus, by making the determination based on the distance from the end face to the welding portion, a welding portion where spot welding by the spot welding machine is impossible can be excluded from the target for specifying the spot welding position 11.

[0049] Note that the spot welding machine includes a single-phase AC type, a three-phase low-frequency type, a single-phase DC type, a three-phase DC type, an inverter type, or a capacitor type spot welding machine, etc. As an example, the server memory 23 stores a table indicating the predetermined distance for each spot welding machine. Further, the determination unit 22C may determine which spot welding machine performs spot welding based on the model data D1. Alternatively, the spot welding machine for performing spot welding may be predetermined according to the plate thickness, material, or supplier.

[0050] Further, the determination condition may be that the distance from the welding portion to the bending position is equal to or greater than a predetermined distance. For example, the determination unit 22C determines whether bending of the article is necessary from the model data D1. When bending is performed, the determination unit 22C specifies the bending position. Further, when the distance from the edge of the welding portion to the bending position is equal to or greater than a predetermined distance, the determination unit 22C determines that spot welding is possible. The predetermined distance varies depending on the spot welding machine used for the predetermined welding, and is, for example, 10.0 mm. Thus, by making the determination based on the distance from the bending position to the welding portion, a welding portion where spot welding by the spot welding machine is impossible can be excluded from the target for specifying the spot welding position 11.

[0051] For example, the determination unit 22C determines whether bending is necessary at the boundary between adjacent parts that are bent or folded, based on predetermined priority conditions. For example, the priority conditions may be prioritizing aesthetic appearance or prioritizing low cost. If the condition prioritizes aesthetic appearance, it is important to avoid rounding the bent area, which would impair the aesthetic appearance. Therefore, the determination unit 22C determines that bending is unnecessary and that welding should be performed at the boundary between adjacent parts. If the condition prioritizes low cost, it is important to reduce the amount of welding required to lower the manufacturing cost. Therefore, the determination unit 22C determines that bending is necessary. In this case, the determination unit 22C identifies the boundary between adjacent parts as the bending location.

[0052] Furthermore, the criteria for judgment may be set based on the Japan Welding Society standards. For example, in this case, the criterion for judgment is that the welded portion has a length equal to or greater than a predetermined length. As an example, the predetermined length is determined by the predetermined pitch and minimum edge distance based on the Japan Welding Society standards. Specifically, if the small part P3 and the large part P4 are both made of aluminum and have a plate thickness of 0.4 mm, the minimum edge distance is 5.0 mm and the predetermined pitch is 13.0 mm. Therefore, in order to perform spot welding, a length of 23.00 mm is required, which is the sum of the minimum edge distance of 5.0 mm from each edge of the welded portion and the predetermined pitch of 13.0 mm between at least two spot welding positions 11.

[0053] The determination unit 22C then determines that spot welding is possible if the longest distance from edge to edge of the welded area is equal to or greater than a predetermined length (23.00 mm in the above example). By making this determination based on the length of the welded area, welded areas where spot welding is impossible because the welding pitch P falls below the minimum pitch can be excluded from the specified target of the spot welding position 11. Furthermore, the predetermined length may be determined considering the minimum number of welding points based on the Japan Welding Society standards. For example, the minimum number of welding points is two per side. By setting the minimum number of welding points to at least two, the strength of the welded area can be ensured. However, the minimum number of welding points may be three or more.

[0054] Furthermore, if it is impossible to perform spot welding on the welded area, the determination unit 22C may, as an error handling measure, display an error to the client terminal 40. This allows the user to recognize that spot welding is impossible and to consider changing to an alternative welding method. As an example, the determination unit 22C may display a number or string of characters as an error indication (for example, "Error 1: Spot welding cannot be performed") on the client terminal 40. Alternatively, the determination unit 22C may display the error to the client terminal 40 by outputting an audio message.

[0055] [Generation Means] The generation unit 22E generates welding pattern data D2 indicating the spot welding positions 11. This allows the spot welding positions 11 to be presented to the user based on the welding pattern data D2. Furthermore, the spot welding positions 11 can be notified to the supplier based on the welding pattern data D2. For example, the welding pattern data D2 can be used to display or generate a three-dimensional object or two-dimensional object, a three-dimensional CAD model, or a two-dimensional CAD model of an article or part. This data can be passed to the supplier or displayed on the supplier's terminal to notify the supplier of the spot welding positions 11. Below, an example of generating a three-dimensional object 15 based on the welding pattern data D2 will be described with reference to Figure 5.

[0056] The generation unit 22E generates welding pattern data D2 so as to add spot welding objects indicating spot welding positions 11 to the three-dimensional object 15. For example, a spot welding object is an element such as a pattern that has no height, or an object that has height. Normally, spot welding objects are not included in the model data D1 uploaded by the user. Alternatively, the model data D1 may include at least one spot welding object.

[0057] For example, the generation unit 22E adds a spot welding object to the spot welding position 11 (for example, the coordinates on the three-dimensional object 15) specified by the identification unit 22B. The generation unit 22E may also generate welding pattern data D2 by modifying the model data D1. Alternatively, the generation unit 22E may generate welding pattern data D2 separately from the model data D1.

[0058] [Presentation means] The presentation unit 22F presents the spot welding positions 11 to the user based on the welding pattern data D2 generated by the generation unit 22E. For example, the presentation unit 22F causes the display device 46 to display a three-dimensional object 15 that includes spot welding objects indicating the spot welding positions 11. In the example of Figure 5, the three-dimensional object 15 includes spot welding objects indicating five spot welding positions 11.

[0059] Alternatively, the display unit 22F may present the spot welding position 11 to the user by displaying the coordinates of the spot welding position 11 on the display device 46. Alternatively, the display unit 22F may present the spot welding position 11 to the user by displaying the model or object of each component, including the spot welding object, on the display device 46.

[0060] [Quotation Method] The quotation unit 22G creates quotation information, including the delivery date of the goods, as part of the quotation process, and stores it in the server memory 23. For example, the delivery date is the number of days required until shipment, the date of shipment, or the date of delivery to the user. The quotation information also includes the price of the goods. For example, the quotation unit 22G creates quotation information for the goods when welding the welded parts, based on the number of spot welding positions 11 based on the welding pattern data D2. The presentation unit 22F then presents the quotation information to the user by displaying it on the display device 46. Alternatively, the presentation unit 22F may present the quotation information to the user by outputting sound to the display device 46.

[0061] For example, the estimation unit 22G estimates the delivery date based on the number of days required to produce all parts, plus the number of days obtained by multiplying the number of spot welding positions 11 by the time required for welding each position, and the number of days required for bending, etc. For example, if the number of spot welding positions 11 increases, the delivery date for the goods will be longer. Alternatively, the estimation unit 22G estimates the price of all parts, plus the cost obtained by multiplying the number of spot welding positions 11 by the welding cost per position, the cost required for bending, and the cost required for transportation, etc. For example, if the number of spot welding positions 11 increases, the price of the goods will be higher. Note that time required for other processing (e.g., wire welding) and other times such as delivery time may be added to the delivery date. In addition, costs required for other processing and other costs such as handling fees may be added to the price.

[0062] Furthermore, the estimation unit 22G estimates a longer delivery time when the linear welding position is specified compared to when only the spot welding position 11 is specified. That is, if the determination unit 22C determines that there is a location where spot welding is impossible, the linear welding position specified by the identification unit 22B is included in the welding pattern data D2. When the linear welding position is included in the welding pattern data D2, the estimation unit 22G estimates a longer delivery time. Since the time required for spot welding is shorter than for linear welding, the accuracy of the estimate can be maintained by estimating a longer delivery time.

[0063] As an example, the estimation unit 22G estimates the delivery date by adding the time required for welding according to the welding length specified based on the line welding position. Alternatively, if the line welding position is specified, the estimation unit 22G may estimate the delivery date by adding the time required for line welding according to the number of spot welds and / or the number of processed surfaces.

[0064] Furthermore, when a user places an order for goods, the estimation unit 22G transmits identification information (e.g., the item's model number) and the quantity to be purchased to the supplier. The estimation unit 22G also transmits a two-dimensional CAD model of the part, generated using the welding pattern data D2, to the supplier's terminal. Alternatively, the estimation unit 22G displays a two-dimensional object of the part, displayed using the welding pattern data D2, on the supplier's terminal.

[0065] Furthermore, the estimation unit 22G may perform processes such as sending delivery instructions for goods to suppliers and billing the user for the purchase price. For example, the estimation unit 22G identifies the model number of an item and creates an order screen as a web page for ordering the item corresponding to the identified model number. The display unit 22F then displays this order screen on the display device 46 of the client terminal 40. When the user orders an item, the estimation unit 22G sends the identified model number and the quantity to the goods manufacturer. The server memory 23 stores the information necessary for the estimate (for example, the price of parts).

[0066] [Client Terminal] Returning to Figure 2, the client terminal 40 comprises a terminal control unit 45 that controls the client terminal 40 and a terminal memory 44 that stores a control program. The terminal control unit 45 is a computer that combines a processor that performs various calculations and operation controls according to a predetermined program with other peripheral devices. The client terminal 40 also comprises a display device 46 and an input device 47.

[0067] For example, the processor of the terminal control unit 45 is, for example, a CPU or MPU, and controls the entire device and comprehensively controls various processes based on a control program stored in the terminal memory 44. The terminal memory 44 also includes RAM, which is a system work memory for the processor to operate, and storage devices such as ROM, HDD, and SSD for storing programs and system software. The terminal control unit 45 can also perform control according to programs stored on portable recording media such as CDs, DVDs, CF cards, and USB memory, or external storage media such as cloud servers on the internet.

[0068] The terminal memory 44 is an external storage device that includes non-volatile storage media (i.e., computer-readable non-temporary storage media) such as a hard disk and a semiconductor storage device. Furthermore, in addition to the control program, the terminal memory 44 stores design programs for creating model data D1 such as CAD software, and various programs such as a web browser.

[0069] The input device 47 includes a keyboard, numeric keypad, and touch panel, and the user uses the input device 47 to create or modify model data D1. The model data D1 created using the input device 47 is then recorded in the terminal memory 44. When information such as quotation information is received from the server 20, the display device 46 displays the quotation information. Furthermore, the display device 46 displays web pages such as welding condition setting screens, quotation screens, and order screens. The user orders goods according to the web pages displayed on the display device 46.

[0070] [Support Processing] Next, the support processing will be explained with reference to Figure 6. First, the user uploads the model data D1 to the server 20. The receiving unit 22A of the server 20 receives the model data D1 from the client terminal 40 (S101) and stores it in the server memory 23. Subsequently, the identification unit 22B of the server 20 retrieves the model data D1 from the server memory 23 and identifies the welding portion to be welded in the model data D1 (S102).

[0071] Subsequently, the determination unit 22C of the server 20 determines whether or not spot welding can be performed on the identified welding area (S103). Then, the identification unit 22B identifies the spot welding positions 11 in the welding area from the model data D1 if spot welding is possible (YES in S104) (S105). Once the spot welding positions 11 have been identified for all welding areas, the generation unit 22E generates welding pattern data D2 indicating the spot welding positions 11 (S106). Then, the presentation unit 22F presents the three-dimensional object 15 including the spot welding positions 11 to the user based on the welding pattern data D2 generated by the generation unit 22E.

[0072] The user can check the spot welding positions 11 and increase or decrease the number of spot welding positions 11. If the user increases or decreases the number of spot welding positions 11 (YES in S107), the identification unit 22B changes the welding pitch P between the multiple spot welding positions 11 (S108). The identification unit 22B then identifies the multiple spot welding positions 11 after changing the welding pitch P (S105). The generation unit 22E then regenerates the welding pattern data D2 indicating the spot welding positions 11 (S106). When regenerating the welding pattern data D2, the generation unit 22E may modify the welding pattern data D2 or generate new welding pattern data D2.

[0073] If the user does not increase or decrease the spot welding position 11 (NO in S107), the estimation unit 22G performs estimation processing (S110). That is, the estimation unit 22G creates estimation information including the delivery date and price of the goods and stores it in the server memory 23. With this, the support processing is completed, and the presentation unit 22F presents the estimation information to the user. When the user performs an operation to order the goods, the estimation unit 22G sends the item number and purchase quantity to the goods supplier.

[0074] Furthermore, if it is impossible to perform spot welding on the welded portion (NO in S104), error processing is performed (S109). Specifically, if it is impossible to perform spot welding on the welded portion, the identification unit 22B identifies the linear welding position in the welded portion as an error processing step. Alternatively, if it is impossible to perform spot welding on the welded portion, the determination unit 22C may cause the client terminal 40 to display an error as an error processing step. After error processing, the generation unit 22E generates welding pattern data D2 indicating the linear welding position to be performed (S106).

[0075] If it is not possible to perform spot welding on a portion of the welded area, the spot welding positions 11 are identified (S105) for the areas where spot welding is possible. Therefore, the generation unit 22E may generate welding pattern data D2 that indicates the spot welding positions 11 in addition to the linear welding positions.

[0076] According to the support system 100 described above, the spot welding locations 11 to be performed can be automatically identified. Therefore, the user can omit the operation of identifying the spot welding locations 11, reducing the man-hours and time required for the design of the product. In addition, by automatically suggesting spot welding, the price can be reduced and the delivery time shortened compared to when linear welding is suggested. Furthermore, distortion of the welded parts of the product can be suppressed compared to when spot welding is performed. Moreover, because the support system 100 suggests spot welding to the user as a priority over other welding methods, it is easier for the user to reduce costs or ensure quality.

[0077] Although the present invention has been described above with reference to the embodiments, the present invention is not limited to the embodiments described above. Inventions modified within the scope that does not contradict the present invention, and inventions equivalent to the present invention are also included in the present invention. Furthermore, each embodiment and each variation, as well as the technical means included in each embodiment or each variation, can be appropriately combined within the scope that does not contradict the present invention.

[0078] For example, welding pattern data D2 may not be created, and only information indicating the spot welding position 11 identified by the identification unit 22B (for example, coordinates on the three-dimensional object 13 or three-dimensional object 15) may be stored in the server memory 23. In this case, the supplier is provided with information indicating the spot welding position 11. The supplier then performs spot welding at the position identified by the received information.

[0079] Furthermore, the display unit 22F may present guarantee items to the user. For example, the display unit 22F may present guarantee items for the appearance of the article, the precision of the processing, and the strength of the article. The guarantee item for the appearance of the article may be presented by displaying a three-dimensional object 13 or three-dimensional object 15 as a predicted finished image of the welded part. Alternatively, the guarantee item for the appearance of the article may be presented by displaying an exemplary object different from the three-dimensional object 13 or three-dimensional object 15. Furthermore, the guarantee item for the appearance of the article may be presented by displaying the nugget diameter and the depth of the weld. The guarantee item for the precision of the processing is presented by displaying the tolerance grade of the ordinary tolerance for metal processed products in accordance with standards such as JIS (Japanese Industrial Standards). The guarantee item for the strength of the article is presented by displaying the inspection system and management system of the supplier.

[0080] Some or all of the above embodiments may also be described as follows, but are not limited to the following:

[0081] (Note 1) A support system equipped with a computer that assists in setting welding conditions for an article, wherein the computer receives model data of the article from a client terminal and identifies spot welding locations to be spot welded from the model data.

[0082] (Note 2) The support system according to Note 1, wherein the computer determines whether or not it is possible to perform the spot welding on the welding portion in the model data, identifies the spot welding position on the welding portion if it is possible to perform the spot welding, and generates welding pattern data indicating the spot welding position.

[0083] (Note 3) The support system described in Note 2, wherein the computer identifies the portion where the surfaces of multiple parts included in the article overlap as the welded portion.

[0084] (Note 4) The support system according to Note 2 or 3, wherein the computer determines that spot welding is possible when the distance from the welding portion to the position corresponding to the end face of the article is greater than or equal to a predetermined distance.

[0085] (Note 5) The support system according to any one of Notes 2 to 4, wherein the computer identifies the bending position of the article from the model data and determines that spot welding is possible if the distance from the welding portion to the bending position is greater than or equal to a predetermined distance.

[0086] (Note 6) The support system according to any one of Notes 2 to 5, wherein the computer determines that spot welding is possible when the welding portion has a length equal to or greater than a predetermined length.

[0087] (Note 7) The support system according to any one of Notes 1 to 6, wherein the computer identifies a plurality of spot welding locations and accepts an operation to increase or decrease the number of spot welding locations from the client terminal.

[0088] (Note 8) The support system according to Note 7, wherein the computer shortens the welding pitch between the plurality of spot welding positions when it accepts the increase operation, and lengthens the welding pitch when it accepts the decrease operation.

[0089] (Note 9) The support system according to any one of Notes 2 to 6, wherein the computer causes the client terminal to display an error or identifies the line welding position in the welded portion when it is impossible to perform the spot welding on the welded portion.

[0090] (Note 10) The support system according to any one of Notes 2 to 6, wherein the computer determines that it is impossible to perform the spot welding on the welded portion, identifies the linear welding position on the welded portion, creates an estimate information including the delivery date of the item, and estimates the delivery date to be longer than when only the spot welding position is identified, if the linear welding position is identified.

[0091] (Note 11) A control method for a support system equipped with a computer that assists in setting welding conditions for an article, wherein the computer receives model data of the article from a client terminal and identifies spot welding positions to be performed from the model data.

[0092] (Note 12) A support program for a support system equipped with a computer that assists in setting welding conditions for an article, the support program causing the computer to receive model data of the article from a client terminal and to identify spot welding locations to be spot welded from the model data.

[0093] This application claims priority from Japanese Patent Application No. 2024-168890, filed on 27 September 2024, and incorporates its entire contents as an integral part thereof.

[0094] 11: Spot welding position 22: Server control unit (computer) 40: Client terminal 100: Support system D1: Model data D2: Welding pattern data P: Welding pitch P1: Small part (part) P2: Large part (part) P3: Small part (part) P4: Large part (part) PG: Support program S3: End face S4: End face

Claims

1. A support system equipped with a computer that assists in setting welding conditions for an article, wherein the computer receives model data of the article from a client terminal and identifies spot welding locations to be spot welded from the model data.

2. The support system according to claim 1, wherein the computer determines whether or not it is possible to perform the spot welding on the welding portion in the model data, identifies the spot welding position in the welding portion if it is possible to perform the spot welding, and generates welding pattern data indicating the spot welding position.

3. The support system according to claim 2, wherein the computer identifies a portion where the surfaces of multiple parts included in the article overlap as the welded portion.

4. The support system according to claim 2, wherein the computer determines that spot welding is possible when the distance from the welding portion to the position corresponding to the end face of the article is greater than or equal to a predetermined distance.

5. The support system according to claim 2, wherein the computer identifies the bending position of the article from the model data and determines that spot welding is possible if the distance from the welding portion to the bending position is greater than or equal to a predetermined distance.

6. The support system according to claim 2, wherein the computer determines that spot welding is possible when the welding portion has a length equal to or greater than a predetermined length.

7. The support system according to claim 1, wherein the computer identifies a plurality of spot welding locations and accepts an operation to increase or decrease the number of spot welding locations from the client terminal.

8. The support system according to claim 7, wherein the computer shortens the welding pitch between the plurality of spot welding positions when it accepts the increase operation, and lengthens the welding pitch when it accepts the decrease operation.

9. The support system according to claim 2, wherein the computer causes the client terminal to present an error or identifies the line welding position in the welded portion if it is impossible to perform the spot welding on the welded portion.

10. The support system according to claim 2, wherein the computer determines that it is impossible to perform the spot welding on the welded portion, identifies the linear welding position on the welded portion, creates an estimate information including the delivery date of the item, and estimates the delivery date to be longer than when only the spot welding position is identified, if the linear welding position is identified.

11. A control method for a support system equipped with a computer that assists in setting welding conditions for an article, wherein the computer receives model data of the article from a client terminal and identifies spot welding locations to be spot welded from the model data.

12. A support program for a support system equipped with a computer that assists in setting welding conditions for an article, the support program causing the computer to receive model data of the article from a client terminal and to identify spot welding locations to be spot welded from the model data.

Images