Press-fitting control device

Abstract

A press-fitting control device according to one aspect of the present disclosure controls an operation of a press-fitting device that press-fits, by an approaching operation of a punch to a die, a clinch stud bolt into a hole of a workpiece supported by a robot device on the die, the press-fitting control device comprising: at least one sensor; a first confirmation unit that confirms, on the basis of an output of the sensor, that a pin of the die is inserted into the hole of the workpiece; a second confirmation unit that confirms, on the basis of the output of the sensor, that the clinch stud bolt is at a prescribed position between the die and the punch; and a first permission unit that permits the press-fitting device to perform an approaching operation of the punch to the die when the first confirmation unit confirms that the pin of the die is inserted into the hole of the workpiece and the second confirmation unit confirms that the clinch stud bolt is at the prescribed position between the die and the punch.

Description

Press-fitting control device

[0001] The present disclosure relates to a press-fitting control device.

[0002] When fixing parts such as stud bolts to a workpiece or the like by welding, depending on the way the operator welds, the strength may be insufficient and it may be difficult to maintain stable quality. In order to ensure the stable quality of the member fixing parts such as clinch stud bolts to the workpiece, a press-fitting device for fixing parts such as clinch stud bolts to the holes formed in the workpiece by press-fitting is known (for example, Patent Document 1). The press-fitting operation using the press-fitting device includes operations such as setting the workpiece with respect to the die of the press-fitting device and removing the workpiece into which the part has been press-fitted from the die, and the operator carried out these operations while visually confirming them. However, since the work is carried out by operators with different levels of proficiency, there were variations in the quality of the finished products. Therefore, a proposal for a technology that can stably ensure the quality of the press-fitting operation by the press-fitting device is desired.

[0003] Japanese Patent Laid-Open No. 06-206125

[0004] A proposal for a technology that can stably ensure the quality of the press-fitting operation by the press-fitting device is desired.

[0005] A press-fitting control device according to an aspect of the present disclosure is a press-fitting control device that controls the operation of a press-fitting device that press-fits a clinch stud bolt into a hole of a workpiece supported by a robot device on a die by an approaching operation of a punch to the die, and includes at least one sensor, a first confirmation unit that confirms that a pin of the die is inserted into the hole of the workpiece based on the output of the sensor, a second confirmation unit that confirms that the clinch stud bolt is at a predetermined position between the die and the punch based on the output of the sensor, and a first permission unit that permits the approaching operation of the punch to the die to the press-fitting device when it is confirmed by the first confirmation unit that the pin of the die is inserted into the hole of the workpiece and it is confirmed by the second confirmation unit that the clinch stud bolt is at a predetermined position between the die and the punch.

[0006] Figure 1 is a side view showing an example of a press-fitting system including a press-fitting control device according to this embodiment. Figure 2 is a front view of the press-fitting device of Figure 1. Figure 3 is a hardware configuration diagram of the press-fitting control device according to this embodiment. Figure 4 is a functional configuration diagram of the press-fitting control device according to this embodiment. Figure 5 is a flowchart showing the first half of the control procedure for the press-fitting device and robot device by the press-fitting control device according to this embodiment. Figure 6 is a flowchart showing the second half of the control procedure for the press-fitting device and robot device by the press-fitting control device according to this embodiment. Figure 7 is a flowchart showing another example of the process related to steps S21 to S23 in Figure 5.

[0007] The press-fit control device according to this embodiment will be described below with reference to the drawings. In the following description, components having substantially the same function and configuration will be denoted by the same reference numerals, and redundant explanations will be given only when necessary.

[0008] Referring to Figures 1 and 2, a press-fitting system including a press-fitting control device according to this embodiment will be described. As shown in Figure 1, the press-fitting system is a system that automates the press-fitting operation of parts into a workpiece 100 by retrofitting a robot device 6 and a press-fitting control device 1 that comprehensively controls the press-fitting device 3 and the robot device 6 to an existing press-fitting device 3. The operation procedure for press-fitting using the existing press-fitting device 3 is as follows. First, the workpiece 100 is set on the die (lower tool) 33 by the operator, and a vertically movable pin 34 provided on the die 33 is inserted into a hole made in the workpiece 100. When the operator steps on the foot pedal 8, the press-fitting operation starts, and the holder 37, which was waiting in a standby position behind the position between the punch (upper tool) 35 and the die 33, holding the clinch stud bolt 200 supplied from the parts feeder 39, moves forward, thereby positioning the clinch stud bolt 200 at a predetermined position between the punch 35 and the die 33. Next, the punch 35 approaches (descends) toward the die 33, and the clinch stud bolt 200 is press-fitted into the hole in the workpiece 100. After confirming that the punch 35 has returned to its retracted position, the operator removes the workpiece 100, which is now fixed with the clinch stud bolt 200 press-fitted, from the die 33, completing the press-fitting process. The press-fitting system is equipped with a changeover switch 9 to switch between three modes: a first mode in which only operation by the foot pedal 8 is enabled and control by the press-fitting control device 1 is disabled; a second mode in which operation by the foot pedal 8 is disabled and control by the press-fitting control device 1 is enabled; and a third mode in which both operation by the foot pedal 8 and control by the press-fitting control device 1 are disabled. By switching modes using the changeover switch 9, for example, the operator can set the first mode when they need to manually operate the press-fitting device 3, set the second mode when they want to automate the press-fitting process by the press-fitting device 3, and set the third mode when they do not want to move the press-fitting device 3, such as during maintenance. In this way, workers can perform their tasks more safely by setting the mode according to the situation.

[0009] The robot device 6 is primarily responsible for loading the workpiece 100 into the press-fitting device 3 and unloading the workpiece 100 with the parts pressed into it from the press-fitting device 3. The press-fitting control device 1 is responsible for various verification tasks that were previously performed by an operator, from before the workpiece 100 is loaded into the press-fitting device 3 by the robot device 6 until the workpiece 100 with the parts pressed into it is unloaded from the press-fitting device 3. The press-fitting control device 1 also permits predetermined operations from the press-fitting device 3 and the robot device 6 according to the results of the verification tasks, and selects and instructs one of several operations. In this embodiment, the workpiece 100 is a rectangular plate with holes, and the part is a clinch stud bolt 200. Of course, the workpiece 100 and the part are not limited to these. In this specification, the member to be press-fitted may be referred to as the workpiece 100, and the member to be press-fitted may be referred to as the clinch stud bolt 200.

[0010] As shown in Figures 1 and 2, the press-fit control device 1 includes a camera device 5 and an information processing device 7, which acts as a control device that performs various verification operations based on images captured by the camera device 5 and controls the operating timing of the press-fit device 3 and the robot device 6 according to the results of the verification operations. The camera device 5 and the information processing device 7 constitute the press-fit control device 1. Although the specification states that the press-fit control device 1 performs various information processing operations, these various information processing operations are mainly performed by the information processing device 7. The various verification operations include verifying whether the punch 35 constituting the press-fit device 3 is in a predetermined retracted position, verifying whether the pin 34 of the die 33 constituting the press-fit device 3 is inserted into the hole in the workpiece 100, verifying whether the clinch stud bolt 200 is positioned in a predetermined position between the die 33 and the punch 35, and verifying whether the clinch stud bolt 200 has been properly press-fitted into the workpiece 100. To enable these verification tasks to be performed automatically based on the images captured by the camera device 5, the camera device 5 is fixed to the frame 4 in a position that includes the retracted position of the punch 35, the position of the clinch stud bolt 200, and the pin 34 of the die 33 in its field of view.

[0011] Figure 3 shows the hardware configuration of the press-fit control device 1. As shown in Figure 3, the press-fit control device 1 has a processor 11. RAM 12, ROM 13, storage device 14, and various interfaces 15 are connected to the processor 11 via a system bus 10. A camera device 5, a robot device 6, a press-fit device 3, a foot pedal 8, and a changeover switch 9 are connected to the processor 11 via the interface 15, enabling data communication between the press-fit control device 1 and these devices. The processor 11 is composed of, for example, a CPU (Central Processing Unit) and a GPU (Graphics Processing Unit). RAM 12 functions as the main memory of the processor 11, a work area 100, etc. ROM 13 stores the BIOS (Basic Input Output System) and operating system program (OS) executed by the processor 11. Storage device 14 stores a control program that describes a series of control procedures related to the press-fit operation. The various data stored in the storage device 14 may be distributed to users by recording them on removable media (non-temporary storage media) such as USB, or by downloading them to the press-fit control device 1 via a network such as the Internet. In this embodiment, the camera device 5 is one of the devices that make up the press-fit control device 1, but the camera device 5 may be an external device independent of the press-fit control device 1. In other words, the press-fit control device 1 may only have the functions related to the information processing device 7. Also, the camera device 5 may be connected to the robot device 6, and image data captured by the camera device 5 may be taken up by the press-fit control device 1 via the robot device 6.

[0012] Figure 4 shows the functional configuration of the press-fit control device 1. As shown in Figure 4, the processor 11 includes a control unit 110 that comprehensively controls the processing of each part related to the control process by executing a control program stored in the storage device 14, an image data receiving unit 111 that receives image data from the camera device 5, a robot information receiving unit 112 that receives robot information from the robot device 6, a press-fit device information receiving unit 113 that receives press-fit device information from the press-fit device 3, a transmission unit 114 that transmits signals generated by the signal generation unit 126 to the robot device 6 and the press-fit device 3, a first confirmation unit 121 that performs a confirmation process to determine whether the punch 35 is in a predetermined retracted position based on the image data captured by the camera device 5, and a die The device functions as a second verification unit 122 which performs a verification process to confirm whether the pin 34 of the 33 is inserted into the hole in the workpiece 100; a third verification unit 123 which performs a verification process to confirm whether the clinch stud bolt 200 is positioned in a predetermined location between the die 33 and the punch 35 based on the data of the image captured by the camera device 5; a fourth verification unit 124 which performs a verification process to confirm whether the clinch stud bolt 200 has been properly press-fitted into the workpiece 100 based on the data of the image captured by the camera device 5; and a signal generation unit 126 which reads (generates) various signals (permission signals, instruction signals, etc.) from the storage device 14 according to the verification results of the first verification unit 121, the second verification unit 122, the third verification unit 123, and the fourth verification unit 124. The ordinal numbers such as "first" and "second" attached to each verification unit are attached in the specification to identify each verification unit, and the ordinal numbers themselves have no particular meaning, and some may differ from the ordinal numbers attached to each verification unit in the claims.

[0013] The first confirmation unit 121 recognizes the shape and characteristics of the punch 35 from the captured image and identifies the current position of the punch 35 on the captured image. The first confirmation unit 121 compares the identified current position with the retracted position of the punch 35 on the captured image when the punch 35 is in the retracted position, and confirms that the punch 35 is in the retracted position if the current position matches the retracted position, or if the distance between the current position and the retracted position is less than a predetermined value. When the first confirmation unit 121 confirms that the punch 35 is in the retracted position, the signal generation unit 126 generates a permission signal indicating permission to load the workpiece 100 onto the die 33, and the transmission unit 114 transmits the permission signal generated by the signal generation unit 126 to the robot device 6.

[0014] The second verification unit 122 detects the hole in the workpiece 100 and the contour of the pin 34 provided on the die 33 from the captured image, and calculates the displacement between the position of the pin 34 and the center position of the hole in the workpiece 100. The second verification unit 122 confirms that the pin 34 of the die 33 is inserted into the hole in the workpiece 100 if the calculated displacement is less than a predetermined value. On the other hand, the second verification unit 122 confirms that the pin 34 of the die 33 is not inserted into the hole in the workpiece 100 if the calculated displacement is greater than or equal to the predetermined value. Furthermore, the second verification unit 122 confirms that the pin 34 of the die 33 is caught in the hole in the workpiece 100 if the calculated displacement is greater than or equal to the predetermined value and less than a first value, and confirms that the pin 34 of the die 33 is not caught in the hole in the workpiece 100 if the calculated displacement is greater than or equal to the first value. Of course, the second verification unit 122 may employ image processing methods such as edge detection processing and pattern matching processing to confirm whether the pin 34 provided on the die 33 is inserted into, caught in, or not caught in the hole of the workpiece 100. Of course, the second verification unit 122 can also confirm that the pin 34 of the die 33 is not inserted into the hole of the workpiece 100 if it cannot recognize the outline of the pin 34 from the captured image.

[0015] The third verification unit 123 recognizes the shape and characteristics of the clinch stud bolt 200 from the captured image and identifies the current position of the clinch stud bolt 200 on the captured image. The third verification unit 123 compares the identified current position with the position of the clinch stud bolt 200 on the captured image when the clinch stud bolt 200 is previously placed in a predetermined position. If the current position matches the position, or if the distance between the current position and the position is less than a predetermined value, it confirms that the clinch stud bolt 200 is placed in the position. If the distance is greater than or equal to the predetermined value, it confirms that the clinch stud bolt 200 is not placed in the position.

[0016] When the second verification unit 122 confirms that the pin 34 of the die 33 is inserted into the hole in the workpiece 100, and the third verification unit 123 confirms that the clinch stud bolt 200 is in the position, the signal generation unit 126 generates a permission signal indicating permission to move the punch 35 closer to the die 33 as a press-fitting operation, and the transmission unit 114 transmits the permission signal generated by the signal generation unit 126 to the press-fitting device 3.

[0017] The fourth verification unit 124 recognizes the shape of the head and press-fit surface of the clinch stud bolt 200 from the captured image and compares them with their reference shapes when the clinch stud bolt 200 is properly press-fitted into the workpiece 100. For example, the fourth verification unit 124 confirms that the clinch stud bolt 200 has been properly press-fitted into the workpiece 100 when the shape of the head of the clinch stud bolt 200 is not deformed relative to the reference shape. On the other hand, the fourth verification unit 124 confirms that the clinch stud bolt 200 has not been properly press-fitted into the workpiece 100 when the shape of the head of the clinch stud bolt 200 is significantly deformed relative to the reference shape.

[0018] When the fourth verification unit 124 confirms that the clinch stud bolt 200 has been properly pressed into the workpiece 100, and the first verification unit 121 confirms that the punch 35 is in the retracted position, the signal generation unit 126 generates a permission signal indicating permission to eject the normal workpiece 100 from the die 33, and the transmission unit 114 transmits the permission signal generated by the signal generation unit 126 to the robot device 6. On the other hand, when the fourth verification unit 124 confirms that the clinch stud bolt 200 has not been properly pressed into the workpiece 100, and the first verification unit 121 confirms that the punch 35 is in the retracted position, the signal generation unit 126 generates a permission signal indicating permission to eject the abnormal (defective) workpiece 100 from the die 33, and the transmission unit 114 transmits the permission signal generated by the signal generation unit 126 to the robot device 6.

[0019] The verification methods used by the first verification unit 121, the second verification unit 122, the third verification unit 123, and the fourth verification unit 124 are not limited to those described above. For example, various known methods such as pattern matching may be used as the image processing method.

[0020] The following describes the control procedure of the press-fitting device 3 and the robot device 6 by the press-fitting control device 1 when automatically press-fitting a clinch stud bolt 200 into a workpiece 100 using the press-fitting device 3, with reference to Figures 5 and 6. When the press-fitting device 3, the robot device 6, and the press-fitting control device 1, which constitute the press-fitting system, are started and the user inputs an instruction to start the press-fitting operation to the press-fitting control device 1, the press-fitting control device 1 sequentially executes the following processes.

[0021] First, when the image data receiving unit 111 receives the image data captured by the camera device 5 (S11), the first confirmation unit 121 performs a confirmation process based on the received image data to check whether the punch 35 is in a predetermined retracted position (S12). If the punch 35 is not in the retracted position (S13; No), the signal generation unit 126 generates a rise instruction signal to instruct the punch 35 to rise, and the rise instruction signal is transmitted to the press-fitting device 3 by the transmission unit 114 (S14). When the press-fitting device 3 receives the rise instruction signal from the press-fitting control device 1, it raises the punch 35 toward the retracted position and transmits a rise completion signal to the press-fitting control device 1 indicating that the operation of raising the punch 35 to the retracted position has been completed. When the press-fitting device information receiving unit 113 receives the rise completion signal (S15), the overall control unit 110 returns the process to step S11. On the other hand, when the punch 35 is in the retracted position (S13; Yes), the signal generation unit 126 generates a loading permission signal that permits the loading operation of the workpiece 100 onto the die 33 of the press-fitting device 3, and transmits it to the robot device 6 by the transmission unit 114 (S16). When the robot device 6 receives the loading permission signal from the press-fitting control device 1, it grasps the workpiece 100 with the hand 61 and executes an operation to load the workpiece 100 onto the die 33 so that the pin 34 on the die 33 is inserted into the hole in the workpiece 100, and transmits a loading completion signal to the press-fitting control device 1 indicating that the loading operation of the workpiece 100 has been completed.

[0022] When the robot information receiving unit 112 receives a loading completion signal (S17), the image data receiving unit 111 receives the image data captured by the camera device 5 (S18). Based on the received image data, the second verification unit 122 performs a verification process to confirm whether the pins 34 of the die 33 are inserted into the holes of the workpiece 100 (S19). If the pins 34 of the die 33 are not inserted into the holes of the workpiece 100 (S20; No), the second verification unit 122 identifies the position of the workpiece 100 based on the captured image (S21), and the signal generation unit 126 generates a position correction instruction signal to instruct the workpiece 100 to be corrected. The position correction instruction signal, along with the position information of the workpiece 100, is transmitted to the robot device 6 by the transmission unit 114 (S22). In other words, the robot device 6 is instructed to redo the movement of the workpiece 100. When the robot device 6 receives a position correction instruction signal from the press-fit control device 1 along with the position information of the workpiece 100, it executes a position correction operation, moves the workpiece 100 to a position corresponding to the position information of the workpiece 100, and transmits a position correction completion signal to the press-fit control device 1 indicating that the position correction operation has been completed. When the robot information receiving unit 112 receives the position correction completion signal (S23), the overall control unit 110 returns the process to step S18. Meanwhile, when the pin 34 of the die 33 is inserted into the hole of the workpiece 100 (S20; Yes), the signal generation unit 126 generates an insertion permission signal that permits the insertion operation of the clinch stud bolt 200, and transmits it to the press-fit device 3 by the transmission unit 114 (S24). When the press-fit device 3 receives the insertion permission signal from the press-fit control device 1, it moves the holder 37 to position the clinch stud bolt 200 in a predetermined position, and transmits an insertion completion signal to the press-fit control device 1 indicating that the insertion operation of the clinch stud bolt 200 has been completed.

[0023] When the press-fitting device information receiving unit 113 receives a loading completion signal (S25), the image data receiving unit 111 receives the image data captured by the camera device 5 (S26). Based on the received image data, the third confirmation unit 123 performs a confirmation process to determine whether the clinch stud bolt 200 is positioned in the designated location (S27). If the clinch stud bolt 200 is not positioned in the designated location (S28; No), the overall control unit 110 returns the process to step S24, and steps S24 to S27 are repeated. On the other hand, if the clinch stud bolt 200 is positioned in the designated location (S28; Yes), the signal generation unit 126 generates a press-fitting permission signal that permits the press-fitting operation of the clinch stud bolt 200 into the workpiece 100, and the transmission unit 114 transmits it to the press-fitting device 3 (S29). When the press-fitting device 3 receives a press-fitting permission signal from the press-fitting control device 1, it performs an approach operation to bring the punch 35 closer to the die 33, and then transmits a press-fitting completion signal to the press-fitting control device 1 indicating that the press-fitting operation has been completed, by returning the punch 35 to the retracted position.

[0024] When the press-fitting device information receiving unit 113 receives a press-fitting completion signal (S30), the image data receiving unit 111 receives the image data captured by the camera device 5 (S31). Based on the received image data, the first confirmation unit 121 performs a confirmation process to determine whether the punch 35 is in a predetermined retracted position (S32). If the punch 35 is not in the retracted position (S33; No), the signal generation unit 126 generates a rise instruction signal to instruct the punch 35 to rise, and the rise instruction signal is transmitted to the press-fitting device 3 by the transmission unit 114 (S34). When the press-fitting device 3 receives the rise instruction signal from the press-fitting control device 1, it performs an operation to raise the punch 35 toward the retracted position and transmits a rise completion signal to the press-fitting control device 1 indicating that the operation to raise the punch 35 to the retracted position has been completed. When the press-fitting device information receiving unit 113 receives the rise completion signal (S35), the overall control unit 110 returns the process to step S31. On the other hand, when the punch 35 is in the retracted position (S33; Yes), the fourth confirmation unit 124 performs a confirmation process based on the image data received in process S31 to confirm whether the clinch stud bolt 200 has been properly pressed into the workpiece 100 (S36). If the clinch stud bolt 200 has not been properly pressed into the workpiece 100 (S37; No), the signal generation unit 126 generates a second discharge instruction signal instructing the workpiece 100 to be moved to the second position where the defective product is placed, and the transmission unit 114 transmits this signal to the robot device 6 (S38). When the robot device 6 receives the second discharge instruction signal from the press-fit control device 1, it performs an operation to discharge the workpiece 100 to the second position and transmits a second discharge completion signal to the press-fit control device 1 indicating that the discharge operation of the workpiece 100 to the second position has been completed. When the robot information receiving unit 112 receives the second unloading completion signal (S39), the press-fitting operation of the clinch stud bolts 200 into the workpiece 100 is completed. On the other hand, when the clinch stud bolts 200 have been properly press-fitted into the workpiece 100 (S37; Yes), the signal generation unit 126 generates a first unloading instruction signal that instructs the unloading operation of the workpiece 100 to the first position where the normal product is placed, and transmits it to the robot device 6 by the transmission unit 114 (S40).When the robot device 6 receives a first discharge instruction signal from the press-fit control device 1, it performs an operation to discharge the workpiece 100 to the first position and transmits a first discharge completion signal to the press-fit control device 1 indicating that the discharge operation of the workpiece 100 to the first position is complete. When the robot information receiving unit 112 receives the first discharge completion signal (S41), the press-fit operation of the clinch stud bolt 200 into the workpiece 100 is completed.

[0025] The processes S11 to S41 described above are repeated each time the clinch stud bolt 200 is pressed into the workpiece 100. In the above description, the process proceeds to the next step after receiving a signal indicating completion of the operation from the robot device 6 or the press-fitting device 3, such as in steps S15, S17, S23, S25, S30, S35, S39, and S41. However, the process may also proceed to the next step automatically after a predetermined time has elapsed since the press-fitting control device 1 sent a permission signal or instruction signal to the robot device 6 and the press-fitting device 3. In addition, although the above description allows the same verification process to be repeated many times, if, for example, the process does not improve even after repeating it a predetermined number of times and the process cannot proceed to the next step, the press-fitting operation may be interrupted as an error.

[0026] The processes related to steps S21 to S23 may also be carried out using the following procedure. Figure 7 is a flowchart showing another example of the processes related to steps S21 to S23 in Figure 5. As shown in Figure 7, based on the captured image, the second verification unit 122 performs a verification operation to check whether the pin 34 of the die 33 is caught in the hole of the workpiece 100. If the pin 34 of the die 33 is not inserted into the hole of the workpiece 100 (S20; No), and furthermore, the pin 34 of the die 33 is not caught in the hole of the workpiece 100 (S51; No), the processes related to steps S21 to S23 are executed, and the control unit 110 returns the process to step S18. On the other hand, if the pin 34 of the die 33 is not inserted into the hole of the workpiece 100 (S20; No), but the pin 34 of the die 33 is caught in the hole of the workpiece 100 (S51; Yes), the signal generation unit 126 generates an oscillation instruction signal to oscillate the workpiece 100, and the transmission unit 114 transmits it to the robot device 6 (S52). When the robot device 6 receives the oscillation instruction signal from the press-fit control device 1, it drives at least one of the robot arm and the robot hand to perform an oscillation operation to oscillate the workpiece 100. This allows the pin 34 of the die 33, which was caught in the hole of the workpiece 100, to be inserted into the hole of the workpiece 100. After performing the oscillation operation of the workpiece 100, the robot device 6 transmits an oscillation completion signal to the press-fit control device 1 indicating that the oscillation operation has been completed. When the robot information receiving unit 112 receives the oscillation completion signal (S53), the overall control unit 110 returns the process to step S18. The processing procedure by the press-fit control device 1 described with reference to Figures 5 and 6 is an example. The procedures described in Figures 5 and 6 may be rearranged as long as each confirmation process by the press-fit control device 1 is performed. In this embodiment, after the first confirmation process in steps S11 to S15 to determine whether the punch 35 is in the retracted position, the workpiece is loaded into the press-fit device 3 by the robot device 6 in steps S16 to S17. Then, in steps S18 to S23, the second confirmation process is performed to determine whether the pin 34 of the die 33 is inserted into the hole in the workpiece 100. Then, in steps S24 to S28, the third confirmation process is performed to determine whether the clinch stud bolt 200 is positioned in a predetermined location between the die 33 and the punch 35.However, the third confirmation process related to steps S24 to S28 may be performed after the first confirmation process related to steps S11 to S15, or in parallel with the first confirmation process. That is, the third confirmation process may be performed based on the image data received in step S11. Furthermore, the procedures described in Figures 5 and 6 may be omitted, or additional procedures may be added. For example, the receiving process in step S17 may be omitted, and after sending a workpiece loading permission signal to the robot device 6 in step S16, the process may proceed to step S18 after a predetermined time has elapsed. Similarly, the receiving process in step S30 may be omitted, and after sending a press-fitting permission signal to the press-fitting device 3 in step S29, the process may proceed to step S31 after a predetermined time has elapsed. Also, if the press-fitting device 3 automatically positions the clinch stud bolts 200 in predetermined positions, the processes related to steps S24 and S25 may be omitted.

[0027] The press-fit control device 1 described above provides the following effects. Specifically, by retrofitting the press-fit control device 1 and the robot device 6 according to this embodiment to an existing press-fit device 3, the press-fitting work by the press-fit device 3 can be completely automated. By automating the press-fitting work by the press-fit device 3, the verification work that was conventionally performed by workers visually can be automatically performed based on images captured by the camera device 5 equipped with the press-fit control device 1. As each process related to the press-fitting work proceeds while verification work based on captured images is performed as needed, the risk of defective products is reduced, and the risk of the device malfunctioning due to the robot device 6 colliding with the press-fit device 3 is also reduced. In particular, verification work such as whether the workpiece 100 is correctly installed in the die 33 and whether the clinch stud bolt 200 is properly press-fitted into the workpiece 100, which are affected by the skill level of the worker, can be automatically performed with a certain level of quality based on captured images. This avoids situations where defective products are overlooked and ensures stable quality of the press-fitting work by the press-fit device. Furthermore, variations in the time required for pressing parts into the workpiece 100 can be reduced, and the overall operation, including the pressing of parts into the workpiece 100, can be made more efficient.

[0028] Furthermore, during the loading operation of the workpiece 100 into the die 33 of the press-fitting device 3 by the robot device 6, it is possible to confirm whether the pin 34 of the die 33 has been inserted into the hole of the workpiece 100 based on the captured image. If the pin 34 of the die 33 has not been inserted into the hole of the workpiece 100, the robot device 6 can be made to repeatedly load the workpiece 100 until the pin 34 of the die 33 has been inserted into the hole of the workpiece 100. This eliminates the need to stop the press-fitting device 3, enabling long-term operation of the press-fitting device 3 and reducing the risk of defective products resulting from the press-fitting operation being performed before the pin 34 of the die 33 has been inserted into the hole of the workpiece 100. Furthermore, if the pin 34 of the die 33 is not inserted into the hole of the workpiece 100, and the pin 34 of the die 33 is not caught in the hole of the workpiece 100, the robot device 6 can be made to perform the workpiece 100 loading operation again. If the pin 34 of the die 33 is caught in the hole of the workpiece 100, the robot device 6 can be made to perform a rocking motion of the workpiece 100. In this way, the robot device 6 can be instructed to perform different types of operations depending on the insertion state of the pin 34 of the die 33 into the hole of the workpiece 100, making the loading operation of the workpiece 100 into the die 33 of the press-fitting device 3 more efficient.

[0029] The press-fit control device 1 according to this embodiment had a single camera device 5. However, the press-fit control device 1 may have a configuration having multiple camera devices 5, each dedicated to a different verification operation. Alternatively, other sensors may be used instead of camera devices 5. For example, it is possible to confirm whether the punch 35 constituting the press-fit device 3 is in a predetermined retracted position based on sensor information such as an infrared sensor or a distance sensor. Similarly, it is possible to confirm whether the clinch stud bolt 200 is positioned in a predetermined location between the die 33 and the punch 35 based on sensor information such as an infrared sensor or a distance sensor. Thus, the press-fit control device 1 according to this embodiment only needs to have at least one sensor from among the camera device 5, infrared sensor, distance sensor, and other sensors.

[0030] With respect to this embodiment and its variations, the following further notes are disclosed. (Note 1) The press-fit control device 1 controls the operation of a press-fit device 3 that press-fits a clinch stud bolt 200 into a hole in a workpiece 100 supported on a die 33 by a robot device 6 by the movement of a punch 35 approaching the die 33, and comprises at least one sensor 5, a first confirmation unit 122 that confirms that a pin 34 of the die 33 is inserted into a hole in the workpiece 100 based on the output of the sensor 5, a second confirmation unit 123 that confirms that the clinch stud bolt 200 is in a predetermined position between the die 33 and the punch 35 based on the output of the sensor 5, and a first permission unit 126 that permits the press-fit device 3 to move the punch 35 towards the die 33 when the first confirmation unit 122 confirms that the pin 34 of the die 33 is inserted into a hole in the workpiece 100 and the second confirmation unit 123 confirms that the clinch stud bolt 200 is in a predetermined position between the die 33 and the punch 35. (Note 2) The press-fit control device 1 described in Note 1 further comprises a third confirmation unit 121 that confirms the punch 35 is in a predetermined retracted position based on the output of a sensor 5 before permitting the press-fit device 3 to allow the punch 35 to approach the die 33, and a second permission unit 126 that permits the robot device 6 to load the workpiece 100 onto the die 33 when the third confirmation unit 121 confirms that the punch 35 is in the predetermined retracted position. (Note 3) The press-fit control device 1 described in Note 1 further comprises a third confirmation unit 121 that confirms the punch 35 is in a predetermined retracted position based on the output of a sensor 5 after permitting the press-fit device 3 to allow the punch 35 to approach the die 33, and a second permission unit 126 that permits the robot device 6 to load the workpiece 100 with the clinch stud bolt 200 pressed into it onto the die 33 when the third confirmation unit 121 confirms that the punch 35 is in the predetermined retracted position.(Note 4) The press-fit control device 1 described in Note 3 further includes a fourth confirmation unit 124 that confirms that the clinch stud bolt 200 has been pressed into the workpiece 100 based on the output of the sensor 5. The second permission unit 126, when the fourth confirmation unit 124 confirms that the clinch stud bolt 200 has been pressed into the workpiece 100, permits the robot device 6 to remove the workpiece 100 from the die 33 to a first position. When the fourth confirmation unit 124 does not confirm that the clinch stud bolt 200 has been pressed into the workpiece 100, it instructs the robot device 6 to remove the workpiece 100 from the die 33 to a second position. (Note 5) In the press-fit control device 1 described in Note 1, the first permission unit 126, when the first confirmation unit 122 confirms that the pin 34 of the die 33 is caught in the hole in the workpiece 100, instructs the robot device 6 to swing the workpiece 100 on the die 33. (Note 6) In the press-fit control device 1 described in Note 1, when the first confirmation unit 122 confirms that the pin 34 of the die 33 has not been inserted into the hole of the workpiece 100, the first permission unit 126 instructs the robot device 6 to redo the movement of the workpiece 100.

[0031] While several embodiments of the present invention have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims and their equivalents.

[0032] 1... Press-fitting control device, 3... Press-fitting device, 4... Stand, 5... Camera, 6... Robot device, 7... Information processing device, 61... Robot hand, 8... Foot pedal, 9... Changeover switch, 110... Overall control unit, 111... Image data receiving unit, 112... Robot information receiving unit, 113... Press-fitting device information receiving unit, 114... Transmitting unit, 121... First verification unit, 122... Second verification unit, 123... Third verification unit, 124... Fourth verification unit, 126... Signal generation unit.

Claims

1. A press-fit control device for controlling the operation of a press-fit device that press-fits a clinch stud bolt into a hole in a workpiece supported on a die by a robotic device by the movement of a punch approaching the die, comprising: at least one sensor; a first confirmation unit that confirms, based on the output of the sensor, that the pin of the die is inserted into the hole in the workpiece; a second confirmation unit that confirms, based on the output of the sensor, that the clinch stud bolt is in a predetermined position between the die and the punch; and a first permission unit that, when the first confirmation unit confirms that the pin of the die is inserted into the hole in the workpiece and the second confirmation unit confirms that the clinch stud bolt is in a predetermined position between the die and the punch, permits the press-fit device to move the punch towards the die.

2. The press-fitting control device according to claim 1, further comprising: a third confirmation unit that confirms, based on the output of the sensor, that the punch is in a predetermined retracted position before permitting the press-fitting device to move the punch towards the die; and a second permission unit that permits the robot device to move the workpiece onto the die when the third confirmation unit has confirmed that the punch is in the predetermined retracted position.

3. The press-fitting control device according to claim 1, further comprising: a third confirmation unit that, after permitting the press-fitting device to move the punch toward the die, confirms that the punch is in a predetermined retracted position based on the output of the sensor; and a second permission unit that, when the third confirmation unit confirms that the punch is in the predetermined retracted position, permits the robot device to remove the workpiece into which the clinch stud bolt has been press-fitted from the die.

4. The press-fitting control device according to claim 3, further comprising a fourth confirmation unit that confirms that the clinch stud bolt has been press-fitted into the workpiece based on the output of the sensor, wherein the second permission unit permits the robot device to remove the workpiece from the die to a first position when the fourth confirmation unit confirms that the clinch stud bolt has been press-fitted into the workpiece, and instructs the robot device to remove the workpiece from the die to a second position when the fourth confirmation unit does not confirm that the clinch stud bolt has been press-fitted into the workpiece.

5. The press-fitting control device according to claim 1, wherein the first permission unit instructs the robot device to perform an oscillating motion of the workpiece on the die when the first confirmation unit confirms that the pin of the die is engaged in the hole of the workpiece.

6. The press-fit control device according to claim 1, wherein the first permission unit instructs the robot device to redo the movement of the workpiece when the first confirmation unit confirms that the pin of the die has not been inserted into the hole of the workpiece.

Images