Binding device and binding program

Abstract

The present invention easily determine whether an intersection point can be bundled.　A binding system (1) is provided with: a binding machine (61) capable of binding a three-dimensional workpiece B including an intersection point P; a robot arm (4) capable of moving the binding machine (61) and the workpiece B relative to each other; a first camera (31) for two-dimensionally observing the workpiece B; and a control device (7). The control device (7) determines whether the intersection point P and the binding machine (61) can approach each other on the basis of information relating to the workpiece B observed by the first camera (31).

Description

Tying Device and Tying Program

[0001] The present disclosure relates to a tying device and a tying program for tying reinforcing bars.

[0002] Conventionally, a tying system that automatically ties the intersections of intersecting reinforcing bars in sequence with a wire to a workpiece in which a plurality of reinforcing bars are combined is known. In this type of tying system, information on tying points, which are the intersections of the reinforcing bars, may be obtained by a sensor or a camera. For example, in the technique described in Patent Document 1, the planar shape of the frontmost surface of the workpiece including the intersections is detected by a three-dimensional camera. Also, in the technique described in Patent Document 2, the coordinates of the intersections are specified from an image of the workpiece taken by a camera.

[0003] U.S. Patent Application Publication No. 2020 / 0013179 Japanese Unexamined Patent Application Publication No. 2023-105958

[0004] By the way, in tying a three-dimensional object to be tied, an object to be tied or the like may be disposed between the intersection and the tying machine, preventing the tying operation of the tying machine. Therefore, it is useful for the smooth progress of the tying operation if it is possible to simply determine whether a given intersection can be tied before tying.

[0005] The present disclosure has been made in view of the above circumstances, and an object thereof is to simply determine whether an intersection can be tied.

[0006] To solve the above-described problems, the present disclosure provides a tying device including: a tying unit capable of tying a three-dimensional object to be tied including intersections; a moving unit relatively movable between the tying unit and the object to be tied; an observing unit for two-dimensionally observing the object to be tied; and a determining unit for determining whether the intersection and the tying unit can approach each other based on information on the object to be tied observed by the observing unit.

[0007] According to the present disclosure, based on information on the object to be tied observed by the observing unit, it is determined whether the intersection in the object to be tied and the tying unit can approach each other. Thereby, based on the determination result of whether they can approach each other, it is possible to determine whether the intersection can be tied. Therefore, it is possible to simply determine whether the intersection can be tied.

[0008] Figure 1 is a perspective view of the main body of the binding system according to the embodiment. Figure 2 is a block diagram showing the schematic control configuration of the binding system according to the embodiment. Figure 3 is a side view of the binding device according to the embodiment. Figure 4 is a perspective view showing an example of a workpiece according to the embodiment. Figure 5 is a diagram showing the rebar arrangement model of the workpiece in Figure 4. Figure 6 is a flowchart showing the binding process procedure according to the embodiment. Figure 7 is a flowchart showing the binding process procedure according to the embodiment. Figure 8 is a diagram showing an example of a workpiece with truss reinforcement arranged on a panel. Figure 9 is a diagram showing an example of an image taken of the workpiece in Figure 8.

[0009] The embodiments of this disclosure will be described below with reference to the drawings.

[0010] [Configuration of the Binding System] Figure 1 is a perspective view of the main body 10 of the binding system 1 according to this embodiment, and Figure 2 is a block diagram showing the schematic control configuration of the binding system 1. As shown in these figures, the binding system 1 binds a workpiece B (object to be bound) in which a plurality of reinforcing bars S are arranged in a three-dimensional grid at the intersections where the plurality of reinforcing bars S intersect. The binding system 1 corresponds to an example of a binding device according to this disclosure. Specifically, the binding system 1 comprises a main body 10 and a control device 7.

[0011] The device body 10 comprises a workpiece holding unit 2, an overall imaging unit 3, a robot arm 4, an individual imaging unit 5, and a binding device 6. Of these, the workpiece holding unit 2 is located inside the frame 11 of the device body 10, while the overall imaging unit 3, robot arm 4, individual imaging unit 5, and binding device 6 are mounted on the frame 11. In the following description, the XYZ directions refer to the orientations shown in Figure 1. The XYZ directions are orthogonal to each other, the XY plane is approximately horizontal, and the Z direction is approximately vertical.

[0012] The frame 11 is formed in the shape of a rectangular parallelepiped, elongated in the X direction, and includes four support columns 12 erected at the four corners in the X and Y directions, and four beams 13 that span the X and Y directions at the upper ends of the support columns 12. Of the area inside the frame 11, approximately half of one side in the X direction (right side in Figure 1) is the shooting area E1 where shooting is performed by the overall shooting unit 3, and the other half (left side in Figure 1) is the binding area E2 where binding work is performed by the robot arm 4 and the binding device 6.

[0013] <Workpiece Holding Section> The workpiece holding section 2 holds the workpiece B and moves the held workpiece B between the shooting area E1 and the binding area E2. In this embodiment, workpiece B is a reinforced concrete structure in which multiple main reinforcements S1 and multiple stirrups S2 are arranged three-dimensionally. Each main reinforcement S1 extends along the X direction, and multiple main reinforcements S1 are arranged in parallel in the Y and Z directions (in the example in Figure 1, three are arranged in parallel in the Y direction and two in the Z direction). Each stirrup S2 is arranged in a strip shape so as to circle the outside of the multiple main reinforcements S1 along the YZ plane, and multiple stirrups S2 are arranged in parallel along the X direction. In workpiece B, before the multiple reinforcements S (main reinforcements S1, stirrups S2) are bound together, each reinforcement S is held by a jig (not shown).

[0014] The workpiece holding unit 2 comprises a holding base 21 for holding the workpiece B, a rail 22 that movably supports the holding base 21, and a drive motor 23 that drives the rail 22. The holding base 21 is formed in the shape of a rectangular plate with its four sides aligned in the X and Y directions. The rail 22 is laid along the X direction and guides the holding base 21 in the X direction. In this embodiment, the rail 22 is laid so that the holding base 21 (workpiece B) can move at least between the shooting area E1 and the binding area E2. However, the rail 22 may be extended to the outside of the frame 11, and the workpiece B may be configured to move to the work processes before and after binding. The drive motor 23 is a drive source for moving the holding base 21. Based on a drive command from the control device 7, the drive motor 23 moves the holding base 21 between the shooting area E1 and the binding area E2. The workpiece holding unit 2 only needs to be able to move the holding base 21 (workpiece B) from the shooting area E1 to the binding area E2.

[0015] <Overall Imaging Unit> The overall imaging unit 3 images the entire workpiece B in the imaging area E1. Specifically, the overall imaging unit 3 comprises a first camera 31 positioned above the imaging area E1 and a moving mechanism 32 that movably supports the first camera 31. The first camera 31 is positioned facing downward and images the workpiece B held by the workpiece holding unit 2 from above in the imaging area E1. The first camera 31 in this embodiment is a compound-lens (e.g., quad-lens) stereo camera that acquires distance information in the depth direction (vertical direction) along with image information (monochrome image) in the XY plane and outputs it to the control device 7. The first camera 31 corresponds to an example of the observation unit according to this disclosure.

[0016] The moving mechanism 32 includes a Y-direction slider 33 that extends along the Y direction. The Y-direction slider 33 is spanned on a beam 13 along the X direction and is supported on the beam 13 so as to be movable in the X direction. The first camera 31 is suspended from the Y-direction slider 33 so as to be movable in the Y direction. Based on a control command from the control device 7, the moving mechanism 32 drives a drive source (not shown) to move the first camera 31 to a predetermined position (XY coordinates). The moving mechanism 32 is intended to capture images of the entire workpiece B in multiple steps in order to obtain an image of the workpiece B with a desired resolution, as will be described later. Therefore, depending on the performance of the first camera 31 and the shape of the workpiece B, the moving mechanism 32 may only move the first camera 31 in either the X or Y direction, or it may not be provided at all.

[0017] <Robot Arm> The robot arm 4 is equipped with an individual imaging unit 5 and a binding device 6, and moves the individual imaging unit 5 and the binding device 6 to a desired position in the binding area E2. The robot arm 4 is an example of a moving unit according to the present disclosure and is capable of moving the binding device 6 and the workpiece B relative to each other. The robot arm 4 of this embodiment comprises a moving mechanism 46, a robot arm body 40, and a controller 49 (an example of a moving control unit).

[0018] The moving mechanism 46 moves the robot arm body 40. The moving mechanism 46 in this embodiment includes a Y-direction slider 461 that spans the beam 13 of the frame 11. The Y-direction slider 461 moves the robot arm body 40 in the Y direction. However, the specific configuration of the moving mechanism 46 is not particularly limited, and for example, it may include a mechanism that moves the robot arm body 40 in the X direction. Also, if the operating range of the robot arm body 40 can cover the entire binding area E2 without relying on the moving mechanism 46, the moving mechanism 46 may not be provided.

[0019] The robot arm body 40 is a ceiling-mounted vertical articulated robot, installed facing downwards on a Y-direction slider 461 suspended on a beam 13 in the binding area E2. Specifically, the robot arm body 40 comprises a base section 41, multiple arms 42, an end effector 43, and multiple joint sections 44. Note that the robot arm body 40 is not limited to a vertical articulated robot, as long as it is capable of moving the mounted individual imaging unit 5 and binding device 6.

[0020] Multiple arms 42 are connected in series with a base portion 41 as their base end. The base portion 41 is mounted on a Y-direction slider 461 of the moving mechanism 46 and is supported so as to be movable in the Y direction. Multiple joint portions 44 rotatably connect the base portion 41, the multiple arms 42, and the end effector 43. Each joint portion 44 is provided with a motor 441 that drives the arm 42 (or end effector 43) connected to the tip of the joint portion 44, and an encoder 442 that detects the position (speed) of the motor 441 and outputs it to the controller 49. The end effector 43 is connected to the tip of the multiple arms 42. The end effector 43 is equipped with an individual imaging unit 5 and a binding device 6. The specific configuration of the tip of the robot arm body 40 is not particularly limited, as long as it is equipped with an individual imaging unit 5 and a binding device 6. For example, the individual imaging unit 5 may be fixed to the joint 44 at the very tip, and the fastening device 6 may be connected via a tool changer as an end effector.

[0021] The controller 49 controls the operation of each part of the robot arm 4 based on control commands from the control device 7. Specifically, the controller 49 operates each motor 441 and the movement mechanism 46, and outputs information acquired by each encoder 442 to the control device 7. The controller 49 may also locally control the operation of the mounted individual imaging unit 5 and the binding device 6 based on control commands from the control device 7.

[0022] <Individual Imaging Unit> The individual imaging unit 5 is mounted at the tip of the robot arm body 40 and individually photographs the intersections P (see Figure 4) of the reinforcing bars S to be tied in the tying area E2 with a higher resolution than the overall imaging unit 3. Specifically, the individual imaging unit 5 comprises a second camera 51, a lifting motor 52, and a lighting unit 53. The second camera 51 is attached to the end effector 43 of the robot arm 4 facing downwards and photographs the intersections P of the reinforcing bars S to be tied from above. The second camera 51 is provided so as to be movable in the direction of the tip (up and down) relative to the end effector 43. In this embodiment, the second camera 51 is, for example, an RGB camera and acquires image information (color image) of the intersections P to be tied and outputs it to the control device 7. The lifting motor 52 is a drive source that moves (lifts and lowers) the second camera 51 in the direction of the tip (up and down) relative to the end effector 43. The lighting unit 53 is positioned slightly in front of the second camera 51 and around the shooting range, illuminating the object being photographed by the second camera 51. The lighting unit 53 in this embodiment has multiple light sources (floodlights; not shown) that can illuminate the object being photographed by the second camera 51 from different angles.

[0023] <Binding Device> Figure 3 is a side view of the binding device 6. As shown in this figure, the binding device 6 is mounted on the tip of the robot arm body 40. The binding device 6 includes a rebar binding machine (hereinafter simply referred to as "binding machine") 61 that binds the intersections P of the reinforcing bars S that make up the workpiece B with wire W, a slack-forming unit 62 that pulls out the wire W from the reel 63 and forms slack in the wire W between the binding machine 61 and the reel 63, and a control unit 64 (see Figure 2) that executes the binding operation of the binding machine 61 and the slack-forming operation of the wire W of the slack-forming unit 62 according to operation commands from the control device 7.

[0024] The binding machine 61 has an inlet 611 into which two wires W are fed from outside the housing along the feeding direction F shown in the figure. The two wires W fed into the interior from the inlet 611 are wound around the reinforcing bar S, and the two wires W wound around the reinforcing bar S are fed in the reverse feeding direction R to wrap around the reinforcing bar S and cut, after which the wires W are twisted and the reinforcing bar S is bound together with the wires W.

[0025] Therefore, the binding machine 61 includes a wire feeding section for feeding the wire W, a wire guide 612 for guiding the wire W, a curl guide 613 and a guide 614 for winding the wire W around the reinforcing bar S, a cutting section for cutting the wire W wound around the reinforcing bar S, and a wire twisting section for twisting the wire W wound around the reinforcing bar S.

[0026] The wire guide 612 is provided in front of the entrance 611 and guides the two wires W to enter the entrance 611 along the feeding direction F.

[0027] The wire feeding section is located inside the entrance section 611 and feeds two wires W along the feeding direction F by gripping them with a pair of feed gears. The wire feeding section is equipped with a feed motor 615 (see Figure 2) which serves as the drive source. The feed motor 615 drives the two wires W in the feeding direction F by forward rotation, allowing the wires W to be wound around the reinforcing bar S by the curl guide 613 and guide guide 614 located further along the path. The feed motor 615 can also drive the two wires W in the reverse direction R by reverse rotation, allowing the reinforcing bar S to be tightened with the wires W.

[0028] The cutting section is located inside the inlet section 611 and further inside the wire feeding section. The cutting section has a movable blade and a fixed blade (not shown), and the drive source for the movable blade is shared with the wire twisting section. The movable blade can be moved toward the fixed blade by the twisting motor 616 (see Figure 2), which is the drive source for the wire twisting section, to cut the two wires. Note that the drive source for the cutting section may be provided separately and independently.

[0029] The binding device 6 in Figure 3 is supported by an end effector 43 at the tip of the robot arm 4, and performs the binding operation when the pivot axis Zr of the end effector 43 is parallel to the aforementioned Z direction (vertical up and down direction). The binding device 6 is set so that the position where the wire W is bound to the reinforcing bar S is located on the axis of the pivot axis Zr, and during binding, the robot arm 4 positions the binding device 6 so that the intersection point P of the reinforcing bar S is on the axis of the pivot axis Zr.

[0030] The curl guide 613 and the guide 614 are located at the tip of the binding machine 61 (the lower end during binding operation), and are positioned on either side of the aforementioned pivot axis Zr. The base end of the curl guide 613 is positioned beyond the entrance 611 in the feeding direction F, and a guide path is formed on the inside of the curl guide 613 to curl the wire W as it moves from the base end to the tip.

[0031] The guide 614 is positioned opposite the curl guide 613 and receives the wire W curled by the curl guide 613 from its tip, and guides the wire W to the base end while maintaining the curled state, with a guide path formed on its inside. Through the cooperation of the curl guide 613 and the guide 614, the wire W can be deformed into a loop and wrapped around the reinforcing bar S. Furthermore, the curl guide 613 and the guide 614 have straight arms with their inner surfaces parallel to the pivot axis Zr. That is, as will be described later, the inner surfaces of the curl guide 613 and the guide 614 are parallel to the direction of approach between the intersection point P of the reinforcing bar S and the binding machine 61.

[0032] The wire twisting section has a locking member that captures the wire W while it is wound around the reinforcing bar S between the base end of the guide 614 and the base end of the curl guide 613. The locking member is supported inside the binding machine 61 so as to be rotatable around a rotation axis concentric with the aforementioned pivot axis Zr, and is provided with torque for rotational drive by the aforementioned twisting motor 616. After the wire W is cut by the cutting section, the locking member is rotated by the twisting motor 616, twisting both ends of the wire W to bind the reinforcing bar S.

[0033] On one side of the binding machine 61 in the direction along its pivot axis Zr (the upper side during binding), two reels 63 of wire W are rotatably supported side by side. The two reels 63 are each rotatable around an axis perpendicular to the plane of the paper in Figure 3, and are arranged side by side on that axis.

[0034] The slack-forming section 62 is positioned on one side of the binding machine 61 and the two reels 63 in a direction Xw perpendicular to the pivot axis Zr. The slack-forming section 62 includes a first slack-forming section 621 and a second slack-forming section 622 that move past each other, and a slack-forming motor 623 that serves as the driving source for these passing movements.

[0035] The feed direction F of the wire W, as described above, is generally parallel to a plane that is parallel to the pivot axis Zr and the orthogonal direction Xw. Furthermore, the feed direction F of the wire W is inclined somewhat upward in the plane of Figure 3 with respect to the orthogonal direction Xw on the upstream side. Both the first slack-forming section 621 and the second slack-forming section 622 hold rollers over which the two wires W are stretched.

[0036] The first slack-forming section 621 and the second slack-forming section 622 move in a passing motion generally along the feeding direction F, thereby extending the path length of the wire W from the reel 63 to the entrance 611 of the binding machine 61 and allowing the wire W to be pulled out from the reel 63. In addition, the first slack-forming section 621 and the second slack-forming section 622 return to their original positions after the passing motion, thereby providing the wire W with the amount of slack that was pulled out from the reel 63. Note that the slack-forming section 62 is not required.

[0037] Incidentally, the two wires W are required to be fed into the inlet 611 of the binding machine 61 from a direction close to the feeding direction F (i.e., an incidence angle close to the feeding direction F). The feeding direction F is a suitable direction for deforming the wires W into an appropriate loop shape by the curl guide 613 and guide guide 614 located further along that direction of travel. In order to supply the wires W to the inlet 611 of the binding machine 61 along the feeding direction F, the slack-forming section 62 is arranged such that the path from the downstream second slack-forming section 622 to the inlet 611 of the binding machine 61 is along the feeding direction F. When passing each other, the second slack-forming section 622 moves away from the inlet 611 of the binding machine 61 along the feeding direction F.

[0038] Therefore, the binding device 6 is positioned such that the slack-forming portion 62 protrudes significantly from one side (the right side of the page in Figure 3) in the direction Xw perpendicular to the binding machine 61 (rotating axis Zr). The second camera 51 and lighting unit 53 of the individual shooting unit 5 are positioned on the left side of the page in Figure 3 relative to the binding machine 61 of the binding device 6.

[0039] <Control Device> As shown in Figure 2, the control device 7 is a computer that comprehensively controls the bundling system 1. Specifically, the control device 7 comprises an operation unit 72, a display unit 73, a storage unit 76, and a control unit 77. The operation unit 72 is an operating means for the user to perform various operations to operate the control device 7, and includes, for example, a pointing device such as a mouse or a keyboard. The display unit 73 is composed of, for example, a liquid crystal display, an organic EL display, or other display, and displays various information based on display signals from the control unit 77. The display unit 73 may also be a touch panel that serves as part of the operation unit 72, or it may provide audio output.

[0040] The memory unit 76 is a memory composed of RAM (Random Access Memory) and ROM (Read Only Memory), and stores various programs and data, as well as functioning as a work area for the control unit 77. In this embodiment, the memory unit 76 pre-stores a binding program 761, a rebar arrangement model 764, and binding part shape information 765 for executing the binding process described later, as well as image data 762 acquired during the binding process.

[0041] Image data 762 is image information of the workpiece B (reinforcement bars S) acquired by the first camera 31 and the second camera 51 during the execution of the binding process described later. Binding section shape information 765 is information about the size and shape of the binding machine 61, and in this embodiment, it includes information about the two-dimensional shape of the binding machine 61 as viewed from the approach direction (movement direction) between the intersection P and the binding machine 61. Specifically, the two-dimensional shape information of the binding machine 61 is, for example, information about the two-dimensional shape of the curl guide 613 and the guide guide 614 as viewed from the tip side (lower side of Figure 3) along the pivot axis Zr. Reinforcement bar arrangement model 764 is arrangement information of multiple reinforcement bars S in the workpiece B, and is a skeletal model that skeletonizes the reinforcement bars S (showing the virtual centerlines of the reinforcement bars S in three dimensions). An example of the reinforcement bar arrangement model 764 in the case of the workpiece B shown in Figure 4 is shown in Figure 5. The reinforcement bar arrangement model 764 includes, for example, information about the number of reinforcement bars S arranged in each of the XYZ directions. In addition, the data may include information such as the spacing between reinforcing bars S in each of the X, Y, and Z directions, and information about the angle of inclination if the reinforcing bars S are inclined. The data format of the reinforcing bar arrangement model 764 is not particularly limited and may be image data or numerical coordinate data. Furthermore, the storage unit 76 may record various other data acquired during the execution of the tying process described later.

[0042] The control unit 77 is composed of, for example, a CPU (Central Processing Unit) and controls the operation of each part of the control device 7. Specifically, the control unit 77 operates each part of the control device 7 based on the operation content of the operation unit 72, and also loads programs pre-stored in the storage unit 76 and executes various processes in cooperation with the loaded programs.

[0043] [Operation of the Binding System] Next, the operation of the binding system 1 when executing the binding process for binding the workpiece B will be described. FIGS. 6 and 7 are flowcharts showing the procedure of the binding process, and FIGS. 8 and 9 are diagrams for explaining the binding process. Among them, FIG. 8 shows an example of the workpiece B on which the truss bars T are arranged on the panel N, and FIG. 9 shows an example of an image of the workpiece B in FIG. 8 taken.

[0044] In the binding process, a plurality of reinforcing bars S arranged three-dimensionally are bound at the intersection points P (see FIG. 4) where the plurality of reinforcing bars S intersect. This binding process is executed by the control unit 77 of the control device 7 reading out and expanding the binding program 761 from the storage unit 76. Here, it is assumed that the workpiece B is placed in the imaging area E1 in a state of being placed on the holding table 21 in advance (see FIG. 1). In the following, it is assumed that the control device 7 (control unit 77 thereof) exclusively executes each process, but the control main body of the binding process is not particularly limited. For example, each component (control unit) of the binding system 1 may execute it, or the control device 7 and each component may cooperate to execute it.

[0045] As shown in FIG. 6, when the binding process is executed, first, the control unit 77 of the control device 7 captures an image of the workpiece B with the first camera 31 of the overall imaging unit 3 in the imaging area E1 (STEP1). Here, the control unit 77 acquires image data (monochrome image) of the XY plane including distance information of the entire workpiece B with the first camera 31, which is a stereo camera, and stores it in the storage unit 76. More specifically, the control unit 77 controls the moving mechanism 32 according to the size of the workpiece B and the viewing angle of the first camera 31, etc., to move the first camera 31 within the XY plane, and divides the entire workpiece B into a plurality of parts with partial overlap (for example, 4 divisions of 2×2 in each of the X and Y directions) for imaging. Then, the control unit 77 combines the acquired plurality of images to generate an image of the entire workpiece B and stores it in the storage unit 76.

[0046] Next, the control unit 77 calculates the positions of all the intersection points P included in the workpiece B based on the image data acquired in STEP1 (STEP2). Here, the control unit 77 calculates three-dimensional position information including the respective coordinates of XYZ for each intersection point P. Note that in this step, it is sufficient to calculate the positions of a plurality of intersection points P among all the intersection points P that the workpiece B has. Also, here, when calculating the position of the intersection point P, the position may be calculated using the reinforcing bar arrangement model 764. In this case, since it is regarded as the intersection point P when the shape matches the reinforcing bar arrangement model 764, the position can be easily calculated.

[0047] Next, the control unit 77 performs an approachability determination to determine whether each intersection point P whose position was calculated in STEP2 and the tying machine 61 can approach each other (STEP21). Here, based on the shape information of the tying machine 61 stored in advance as the tying portion shape information 765 and the information of the intersection point P observed by the first camera 31, it is determined whether the intersection point P and the tying machine 61 can approach each other. Specifically, in this approachability determination, as shown in FIG. 7, first, the control unit 77 selects the intersection point P to be determined (STEP22).

[0048] Next, the control unit 77 sets a determination area (observation range) G of a predetermined shape centered on the intersection point P to be determined in the image data acquired in STEP1 (STEP23). Here, the determination area G may be set on the two-dimensional image data. Also, the size and shape of the determination area G are not particularly limited, but for example, they are shapes corresponding to the two-dimensional shape of the tying machine 61. The control unit 77 reads the tying portion shape information 765 from the storage unit 76 and sets the determination area G. The determination area G of the present embodiment corresponds to, for example, the two-dimensional shape of the curl guide 613 and the guide guide 614 viewed from the tip side along the rotation axis Zr, and is a long trapezoid, an ellipse, or the like along the curl guide 613 and the guide guide 614. Note that the size and shape of the determination area G may be set in advance or may be selected by the user.

[0049] Next, the control unit 77 determines whether the area ratio occupied by the intersection P in the determination area G is less than a predetermined threshold (STEP 24). Here, "area ratio occupied by the intersection P" refers to the area ratio of the reinforcing bars S (which constitute the intersection P). In other words, in this step, the area ratio of the reinforcing bars S as an obstacle that may prevent the insertion of the binding machine 61 is determined. For example, consider a workpiece B in which truss bars T are arranged on a planar panel N as shown in Figure 8, and an image as shown in Figure 9 is acquired by the first camera 31. In this case, at intersection P1, which coincides with the center of the truss bars T (center left and right in Figure 9), for example, the area ratio of the reinforcing bars S in the trapezoidal determination area G is less than the threshold, and it can be determined that the binding machine 61 can be inserted (approached). On the other hand, at intersection P2, which coincides with the end of the truss bars T (right side in Figure 9), the proportion of the truss bars T is large, and for example, the area ratio of the reinforcing bars S in the elliptical determination area G is greater than or equal to the threshold. In this case, it is determined that the binding machine 61 cannot be inserted into (or approached) the intersection P2.

[0050] In STEP 24, it is preferable for the control unit 77 to determine whether the binding machine 61 can approach (insert) the intersection P in multiple insertion directions (insertion positions). In this case, for example, it is determined whether the curl guide 613 and the guide 614 can be inserted into the intersection P in positions along the 2 o'clock, 4 o'clock, 8 o'clock, and 10 o'clock directions. However, it is assumed that at the intersection P, two reinforcing bars S are arranged along the 3 o'clock-9 o'clock direction and the 12 o'clock-6 o'clock direction. Also, in STEP 24, instead of determining the area ratio of the intersection P (reinforcing bars S), it is possible to determine the area ratio of the space. "Space" refers to a space in which no object is detected and into which the binding machine 61 can be inserted. In other words, in STEP 24, it is possible to determine whether the area ratio of the space into which the binding machine 61 can be inserted in the determination area G is equal to or greater than a threshold.

[0051] In STEP 24, if it is determined that the area ratio occupied by intersection P (reinforcement bar S) within the judgment area G is not less than the threshold (STEP 24; No), the control unit 77 determines that the binding machine 61 cannot approach the intersection P to be judged (STEP 25). The control unit 77 then records the judgment result in the storage unit 76 and proceeds to STEP 27, which will be described later. If it is determined that the area ratio occupied by intersection P within the judgment area G is not less than the threshold, the first camera 31 may be moved and the intersection P may be photographed, and the judgment in STEP 24 may be performed again. In other words, in this case, the first camera 31 is moved by a predetermined amount in the XY plane, for example, to obtain an image of intersection P from a different observation position (shooting position), and the judgment in STEP 24 is performed again using this image. This process may be performed for each intersection P, or it may be performed for multiple intersections P at once. Alternatively, this process may be performed by setting a number of times it can be executed (or a limit on the movement of the first camera 31), and if the number of executions exceeds this limit, it may be determined that the bundling machine 61 cannot approach the intersection P.

[0052] In STEP 24, if it is determined that the area ratio occupied by the intersection P within the determination area G is less than the threshold (STEP 24; Yes), the control unit 77 determines that the bundling machine 61 can approach the intersection P (STEP 26), and records the determination result in the storage unit 76.

[0053] Next, the control unit 77 determines whether or not it has determined whether or not it is possible to approach all the intersection points P whose positions were calculated in STEP 2 (STEP 27). If it determines that it has not determined whether or not it is possible to approach all the intersection points P (STEP 27; No), the control unit 77 proceeds to STEP 22 described above and determines whether or not it is possible to approach the next intersection point P. On the other hand, if it has determined whether or not it is possible to approach all the intersection points P (STEP 27; Yes), the control unit 77 terminates the approachability determination.

[0054] Next, as shown in Figure 6, the control unit 77 drives the drive motor 23 of the workpiece holding unit 2 to operate the holding table 21 and move the workpiece B to the binding area E2 (STEP 3).

[0055] Next, the control unit 77 selects one of the multiple intersections P included in the workpiece B to be bound (STEP 4). Here, the control unit 77 selects one of the multiple intersections P to be bound next, for example, based on a pre-set binding order. However, intersections P that have already been bound (or are recognized as such) and intersections P that were determined in STEP 25 to be inaccessible to the binding machine 61 are excluded from the selection. Hereafter, the intersection P selected here to be bound next will be referred to as the "target intersection Pa".

[0056] Next, in the binding area E2, the control unit 77 moves the second camera 51 of the individual imaging unit 5 mounted on the robot arm 4 closer to the target intersection Pa selected in STEP 4 (STEP 5). Here, the control unit 77 controls the movement of the robot arm 4 based on the position information of the target intersection Pa calculated in STEP 2 and the amount of movement of the workpiece B in the X direction moved in STEP 3, moving the second camera 51 to directly above the target intersection Pa. Then, the control unit 77 controls the operation of the lifting motor 52 to lower the second camera 51 and bring it closer to the target intersection Pa by a predetermined distance. As a result, the target intersection Pa is positioned directly in front of the downward-facing second camera 51, and for example, only the target intersection Pa is within the field of view of the second camera 51 (other intersections P are outside the field of view).

[0057] Next, the control unit 77 uses the second camera 51, which was brought close in STEP 5, to photograph the target intersection Pa and acquire image data (STEP 6). Here, the control unit 77 acquires image data (color image) of the target intersection Pa using the second camera 51 and stores it in the storage unit 76. As a result, image data 762 of the target intersection Pa with a higher resolution than the image data acquired by the first camera 31 in STEP 1 is obtained. In this step, the control unit 77 may also control the lighting unit 53 to photograph the target intersection Pa with multiple different lighting patterns. This allows for the generation of a three-dimensional image based on changes in the patterns of projected and reflected light, and the acquisition of distance information.

[0058] Next, the control unit 77 calculates the position of the target intersection point Pa based on the image data acquired in STEP 6 (STEP 7).

[0059] In calculating the target intersection point Pa, the control unit 77 first detects the edges of the reinforcing bar S, which are the contours of the reinforcing bar S in the image, based on the contrast information contained in the image data of the reinforcing bar S. Here, the contour (edge) refers to the boundary portion between the target reinforcing bar S and the rest of the image. Next, the control unit 77 calculates the reinforcing bar diameter (diameter of the reinforcing bar S) and the reinforcing bar center (central axis along the longitudinal direction of the reinforcing bar S) based on the edge position information. Next, the control unit 77 calculates the position of the target intersection point Pa. Here, the control unit 77 determines the position (coordinates) of the target intersection point Pa as, for example, the intersection of the centers of two reinforcing bars. Here, the dimensions of the target intersection point Pa can also be obtained from the dimensions of the reinforcing bar S in each XY direction. In this way, based on the high-resolution image data acquired by the second camera 51, position information of the target intersection point Pa with higher accuracy than the position information calculated in STEP 2 can be obtained.

[0060] The control unit 77 may also determine here whether or not the target intersection Pa can be tied. In this case, the control unit 77 determines, for example, whether the main part of the tying device 6 (such as the curl guide 613) can be inserted between the two reinforcing bars S from above, based on the intersection angle of the two reinforcing bars S, and determines that tying is possible if insertion is possible. If it is determined that tying is not possible, the control unit 77 moves on to other processes, including interrupting the work or outputting a warning. The control unit 77 may also determine the tying direction based on the position and orientation of the tying device 6, which can insert its main part between the two reinforcing bars S. Furthermore, the control unit 77 may calculate the wire length (including the pull-back length) required to tie the target intersection Pa based on the diameter of the two reinforcing bars S that constitute the target intersection Pa, the intersection angle, etc.

[0061] Next, the control unit 77 moves the binding device 6 closer to the target intersection Pa based on the position information of the target intersection Pa calculated in STEP 7 (STEP 8). Here, the control unit 77 controls the movement of the robot arm 4 and moves the binding device 6 mounted on the end effector 43 closer to the target intersection Pa, instead of the second camera 51. Here, the control unit 77 can position the relevant part of the binding device 6 facing the target intersection Pa with high positional accuracy based on the more accurate position information of the target intersection Pa obtained in STEP 7.

[0062] At this time, the control unit 77 may move the binding machine 61 along a straight line connecting a predetermined position (point) on the binding machine 61 and the center of the target intersection Pa. The predetermined position on the binding machine 61 is, for example, the center position on the pivot axis Zr between the curl guide 613 and the guide guide 614. This allows the binding machine 61 to be moved to the target intersection Pa in the shortest distance. At this time, the control unit 77 may also bring the target intersection Pa and the binding machine 61 closer together with the pivot axis Zr (torsion axis) parallel to the line connecting the predetermined position (point) on the binding machine 61 and the center of the target intersection Pa. This allows the binding machine 61 to be inserted with the pivot axis Zr perfectly perpendicular to the target intersection Pa, enabling strong binding. Furthermore, at this time, the control unit 77 may move the target intersection Pa and the binding machine 61 closer together by having a predetermined movable range (allowable range) in a direction perpendicular to the direction connecting the target intersection Pa and the binding machine 61. In other words, the position of the binding machine 61 approaching the target intersection Pa may be shifted within the allowable range.

[0063] Next, the control unit 77 operates the binding device 6 to bind the target intersection Pa with wire W (STEP 9). At this time, the binding device 6 is positioned opposite the target intersection Pa with sufficiently high positional accuracy, so that the target intersection Pa can be bound appropriately. At this time, the amount of wire W used to bind the target intersection Pa may also be calculated and stored in the storage unit 76. The amount of wire W used can be estimated from the wire feed amount (actual amount excluding the pull-back amount) in the wire feed unit. Also, if the wire length required for binding is estimated in STEP 7 above, this may be used as the amount of wire W used.

[0064] Next, the control unit 77 determines whether or not to terminate the binding process (STEP 10). If it determines not to terminate the process (STEP 10; No), it proceeds to STEP 4 described above. This allows the processes from STEP 4 to S10 to be repeated until, for example, all necessary intersections P are bound. In other words, the selection of the next intersection P to be bound (change of target intersection Pa), the photography of the target intersection Pa, and the binding are performed sequentially. Then, in STEP 10, if it determines to terminate the binding process, for example, by completing the binding of all necessary intersections P (STEP 10; Yes), the control unit 77 terminates the binding process.

[0065] [Technical Effects of This Embodiment] As described above, according to this embodiment, it is determined whether the intersection point P and the binding machine 61 can approach each other based on the information of the workpiece B observed two-dimensionally by the first camera 31 (observation unit). Based on the determination result of whether approach is possible, it is possible to determine whether the intersection point P can be bound. Therefore, it is possible to easily determine whether the intersection point can be bound without requiring complicated calculations such as processing three-dimensional images.

[0066] Furthermore, according to this embodiment, it is determined whether the binding machine 61 can approach the intersection P based on the binding section shape information 765 stored in the memory unit 76 and the information of the intersection P observed by the first camera 31. Therefore, by comparing the information of the intersection P with the shape of the binding machine 61, it is possible to determine with high accuracy whether the binding machine 61 can be inserted into the intersection P, i.e., whether binding is possible.

[0067] Furthermore, according to this embodiment, the binding portion shape information 765 includes information on the two-dimensional shape of the binding machine 61 as viewed from the direction of approach between the intersection P and the binding machine 61. In other words, since the information compared between the intersection P and the binding machine 61 is both two-dimensional information, the amount of information can be reduced and processing can be performed simply.

[0068] Furthermore, according to this embodiment, whether or not the intersection point P (reinforcement bar S) and the binding machine 61 can approach each other is determined based on the area ratio occupied by the intersection point P (reinforcement bar S) in the determination area G (observation range) observed by the first camera 31. This allows for easy determination of whether or not the intersection point P and the binding machine 61 can approach each other by appropriately setting a threshold. Consequently, even if there is an obstacle that could hinder binding, for example, the feasibility of binding can be appropriately determined by taking into account the influence of this obstacle.

[0069] Furthermore, according to this embodiment, it is determined whether the tying machine 61 can approach the intersection P in multiple insertion directions (insertion positions). This allows for the determination of whether tying is possible in other insertion directions, even if it is determined that tying is not possible in one insertion direction.

[0070] Furthermore, according to this embodiment, the control unit 77 moves the binding machine 61 from the observation position (shooting position) of the first camera 31 toward the intersection P. This brings the intersection P and the binding machine 61 closer together.

[0071] Furthermore, according to this embodiment, the binding machine 61 may be brought closer to the intersection P by having a predetermined movable range (allowable range) in a direction perpendicular to the direction connecting the intersection P and the binding machine 61. In other words, the binding machine 61 may be brought closer not by the shortest distance connecting the center of the binding machine 61 and the center of the intersection P, but by slightly shifting it in the direction connecting the curl guide 613 and the guide guide 614. That is, the position of the binding machine 61 approaching the intersection P may be shifted within the allowable range.

[0072] Furthermore, according to this embodiment, the strapping machine 61 may be moved along a straight line connecting a predetermined position (point) on the strapping machine 61 and the center of the intersection point P. This allows the strapping machine 61 to be moved along the shortest distance connecting its center position and the center of the intersection point P.

[0073] Furthermore, according to this embodiment, the binding machine 61 may be brought close to the intersection point P while the pivot axis Zr (torsion axis) is parallel to the line connecting a predetermined position (point) on the binding machine 61 and the center of the intersection point P. This allows the binding machine 61 to be inserted with the pivot axis Zr perfectly perpendicular to the intersection point P, enabling strong binding. In addition, since the binding machine 61 has its narrowest outer shape along the pivot axis Zr, it is easier to bring it close to the intersection point P.

[0074] Furthermore, according to this embodiment, if it is determined that the intersection P and the binding machine 61 cannot approach each other, the first camera 31 may change its observation position and observe the intersection P again. This improves the accuracy of determining whether approach is possible.

[0075] Furthermore, according to this embodiment, the inner surface of the tying machine 61 (curl guide 613, guide guide 614) is parallel (straight arm) to the direction of approach between the intersection P and the tying machine 61. Therefore, when inserting the tying machine 61 into the intersection P, the tying machine 61 is less likely to get caught on reinforcing bars S, etc. Also, even if the position shifts due to the tying operation, the tying machine 61 (curl guide 613, guide guide 614) is less likely to affect the object being tied.

[0076] [Modifications] Although embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments. For example, a three-dimensional model of workpiece B may be generated based on information observed by the first camera 31, and the position of intersection point P may be detected from the three-dimensional model. In this case, the feasibility of subsequent binding (approachability) may be represented on the three-dimensional model. This eliminates the need to process a pre-stored rebar arrangement model. In other words, if, for example, image data cannot be acquired at the required resolution due to environmental conditions such as the amount of incident light, or if differences in the manufacturing precision and orientation of the actual rebar (such as ribs being placed on the upper and lower surfaces) are not accurately reflected in the rebar arrangement model, it may become difficult to make a judgment based on the rebar arrangement model. In this respect, if a simplified model based on captured images is used, it will not be affected by such minor differences in conditions.

[0077] Furthermore, in the bundling process of the above embodiment, the determination of whether STEP 21 can be approached is performed based on the information observed (captured) by the first camera 31. However, the determination of whether it can be approached may also be performed based on the information observed by the second camera 51. In other words, the observation unit according to this disclosure includes a first camera 31 (first observation unit) capable of simultaneously observing multiple intersections P, and a second camera 51 (second observation unit) capable of observing a single intersection P. Furthermore, the observation unit according to this disclosure only needs to be capable of observing the workpiece (object to be bundled) in two dimensions, and the type of sensor is not particularly limited. For example, it may be a sensor using an optical radar system, active stereo method, optical interferometry, lens focusing method, etc., or it may be another sensor using magnetism, ultrasound, X-rays, etc.

[0078] Furthermore, in the above embodiment, the shooting area E1 (first region) and the binding area E2 (second region) are different. However, the shooting area E1 and the binding area E2 may partially overlap or may be a single unit (identical). In this case, the overall shooting unit 3 and the robot arm 4 are configured to move across a range that includes the shooting area E1 and the binding area E2.

[0079] Furthermore, in the above embodiment, the workpiece holding unit 2 moves the workpiece B in the X direction, but the workpiece B may also be moved or rotated in other directions. For example, if the workpiece holding unit 2 can rotate the workpiece B around a horizontal axis to invert the upper and lower surfaces, it can suitably accommodate workpiece B with double reinforcement arrangements on the upper and lower sides.

[0080] Furthermore, in the above embodiment, a workpiece B in which multiple reinforcing bars S are arranged three-dimensionally was given as an example of the object to be bound according to the disclosure. However, the object to be bound according to the disclosure only needs to have intersections P, and does not need to be a multiple reinforcing bar arranged three-dimensionally. Here, an object to be bound in which multiple reinforcing bars are arranged three-dimensionally means one in which multiple intersections are arranged three-dimensionally.

[0081] Alternatively, the robot arm 4 may be configured to select a binding device 6 having an insertion portion (a portion inserted between reinforcing bars S) of a size corresponding to the target intersection Pa. In this case, the robot arm 4 and the binding device 6 are configured to be detachable, and multiple binding devices 6 having insertion portions of different sizes are prepared. The control unit 77 then selects one binding device 6 from among the multiple binding devices 6 that is capable of binding the target intersection Pa to be bound. In this case, the multiple binding devices 6 may be arranged at predetermined positions within the movement range of the robot arm 4, and the exchange of binding devices 6 by the robot arm 4 may be automated.

[0082] Furthermore, in the above embodiment, an example of applying the present disclosure to a robot arm system using a robot arm was described. However, the present disclosure can also be suitably applied to binding methods other than the robot arm system, such as a workpiece transport system that transports workpieces, a gantry system that moves the device using a gantry, and a self-propelled system that moves the entire device, including the binding device, on the workpiece. However, the present disclosure can be more suitably applied to a system in which the entire device is installed (fixed), for example, indoors and the workpiece is moved, as in the above embodiment. In the case of a freely moving body such as a self-propelled robot or outdoor work, applying the structure of the above embodiment may result in problems such as an increased risk of collision of the information acquisition unit, distortion of the acquired signal (camera image) due to collisions, etc., an increase in the overall size of the device, and the need to waterproof the information acquisition unit.

[0083] Furthermore, details shown in the above embodiments can be modified as appropriate without departing from the spirit of the invention.

[0084] Although various embodiments have been described above with reference to the drawings, it goes without saying that the present invention is not limited to these examples. It is clear to those skilled in the art that various modifications or alterations can be conceived within the scope of the claims, and these will naturally also fall within the technical scope of the present invention. Furthermore, the components of the above embodiments may be combined in any way without departing from the spirit of the invention.

[0085] This application is based on a Japanese patent application (JP 2024-230951) filed on December 26, 2024, the contents of which are incorporated by reference within this application.

[0086] This disclosure has the effect of allowing for easy determination of whether or not intersections can be bundled, and is useful for bundling devices and the like.

[0087] 1 Binding system (binding device) 4 Robot arm (moving part) 6 Binding device 7 Control device 31 First camera (observation unit) 51 Second camera (observation unit) 61 Rebar tying machine (binding unit) 76 Memory unit 77 Control unit (determination unit) 613 Curl guide 614 Guidance guide 761 Binding program 762 Image data 764 Rebar arrangement model 765 Binding unit shape information B Work G Determination area (observation range) P, P1, P2 Intersection Pa Target intersection S Rebar S1 Main reinforcement S2 Tie reinforcement Zr Swivel axis (torsion axis)

Claims

1. A binding device comprising: a binding section capable of binding three-dimensional objects to be bound, including an intersection; a moving section capable of moving the binding section and the objects to be bound relative to each other; an observation section for observing the objects to be bound in two dimensions; and a determination section that determines whether the intersection and the binding section can approach each other based on the information of the objects to be bound observed by the observation section.

2. The binding device according to claim 1, further comprising a storage unit for storing shape information of the binding portion in advance, wherein the determination unit determines whether the intersection and the binding portion can approach each other based on the shape information of the binding portion stored in the storage unit and the information of the intersection observed by the observation unit.

3. The binding device according to claim 2, wherein the shape information of the binding portion includes information on the two-dimensional shape of the binding portion as viewed from the direction of approach between the intersection and the binding portion.

4. The binding device according to claim 3, wherein the determination unit determines whether the intersection and the binding unit can approach each other based on the area ratio occupied by the intersection within a predetermined observation range observed by the observation unit.

5. The binding device according to claim 4, wherein the determination unit determines whether the binding unit can approach the intersection in multiple insertion directions.

6. The binding device according to claim 1, further comprising a movement control unit for controlling the moving unit, wherein the movement control unit moves the binding unit from the observation position of the observation unit toward the intersection.

7. The binding device according to claim 6, wherein the movement control unit has a predetermined movable range in a direction perpendicular to the direction connecting the intersection and the binding portion, thereby bringing the intersection and the binding portion closer together.

8. The binding device according to claim 6, wherein the movement control unit moves the binding portion along a straight line connecting a predetermined position in the binding portion and the center of the intersection.

9. The binding device according to claim 6, wherein the binding portion has a twist shaft for binding the objects to be bound, and the movement control unit brings the intersection and the binding portion closer together with the twist shaft parallel to a line connecting a predetermined position in the binding portion and the center of the intersection.

10. The binding device according to claim 1, wherein the observation unit includes a first observation unit capable of simultaneously observing a plurality of intersections and a second observation unit capable of observing a single intersection.

11. If the determination unit determines that the intersection and the binding portion cannot be approached, the observation unit changes its observation position and observes the intersection again, as described in claim 10.

12. The binding device according to claim 1, wherein the inner surface of the binding portion is parallel to the direction of approach between the intersection and the binding portion.

13. A binding program that causes a computer controlling a binding device comprising a binding unit capable of binding three-dimensional objects to be bound including an intersection, a moving unit capable of moving the binding unit and the objects to be bound relative to each other, and an observation unit for observing the objects to be bound in two dimensions, to function as a determination unit that determines whether the intersection and the binding unit can approach each other based on information about the objects to be bound observed by the observation unit.

Images