Binding device and binding program

Abstract

The present invention suitably determines whether or not a binding unit can be inserted into an intersection point.　A binding system (1) comprises: a binding machine (61) that can bind a workpiece B including an intersection point P; a second camera (51) that can observe the workpiece B; and a control device (7). The control device (7) calculates the distance between the intersection point P and a back surface D of the intersection point P on the basis of information observed by the second camera (51), and determines whether or not the binding machine (61) can be inserted into the intersection point P on the basis of the calculated distance and the binding machine (61).

Description

Binding Device and Binding Program

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

[0002] Conventionally, a binding system that automatically binds 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 binding system, information on the binding points, which are the intersections of the reinforcing bars, may be acquired by sensors or cameras. For example, in the technique described in Patent Document 1, the planar coordinates of the intersections are specified by a camera. In addition, in the technique described in Patent Document 2, a Z coordinate camera is provided separately from the XY coordinate camera that obtains the two-dimensional coordinates of the intersections, and the Z coordinates of the intersections are specified by the Z coordinate camera.

[0003] Japanese Patent Application Laid-Open No. 2023-105958 Chinese Patent Application Publication No. 113264212

[0004] By the way, especially in binding a three-dimensional object to be bound, the distance between the intersection and the object on the back side thereof may change, and there is a possibility that the binding machine (binding part) cannot be inserted to a depth at which the intersection can be bound. Therefore, if it is possible to determine whether the binding part can be inserted before binding, it is useful for the safe and smooth progress of the binding operation.

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

[0006] To solve the above-described problems, the present disclosure provides a binding device including: a binding part capable of binding an object to be bound including an intersection; an observation part capable of observing the object to be bound; a calculation part that calculates a first distance between the intersection and the back of the intersection based on information observed by the observation part; and a determination part that determines whether the binding part can be inserted into the intersection based on the first distance calculated by the calculation part and information on the binding part.

[0007] According to the present disclosure, it is possible to suitably determine whether the binding part can be inserted into the intersection.

[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 intersection image data acquired by the second camera. Figure 9 is a diagram showing an example of image data with height information added to the image data in Figure 8. Figure 10 is a diagram for explaining the insertion operation of the binding machine corresponding to the distance between the intersection and the back surface. Figure 11 is a diagram for explaining the insertion operation of the binding machine corresponding to the distance between the intersection and the back surface. Figure 12 is a diagram for explaining the insertion operation of the binding machine corresponding to the distance between the intersection and the back surface.

[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 includes 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 downwards 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 depth information (vertical direction) along with image information (monochrome image) in the XY plane and outputs it to the control device 7.

[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 of this embodiment comprises a moving mechanism 46, a robot arm body 40, and a controller 49.

[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 images 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 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 second camera 51 corresponds to an example of the observation unit according to this disclosure. 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 ahead. That is, the wires W, which have been curled into an arc shape by the curl guide 613, are fed from the curl guide 613 towards the guide guide 614 and inserted into the guide guide 614. The feed motor 615 can also drive the two wires W in the reverse feeding 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. Hereinafter, the tip portion of the tying machine 61 that is inserted into the intersection P (the portion that is inserted between the reinforcing bars S that make up the intersection P), including the curl guide 613 and the guide 614, will be referred to as the insertion portion 61T.

[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 unit 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 bar S) acquired by the first camera 31 and the second camera 51 during the execution of the binding process described later. Binding section information 765 is information related to the binding machine 61, and includes information on the insertion section 61T of the binding machine 61 that is inserted into the intersection P. The information on the insertion section 61T includes information on the insertion orientation into the intersection P in a plan view (for example, the 2 o'clock direction L1 described later; see Figure 8) and information on the insertion length Hm of the insertion section 61T inserted into the intersection P (see Figure 10).

[0042] The reinforcing bar arrangement model 764 is arrangement information of a plurality of reinforcing bars S in the workpiece B, and is a skeleton model in which the reinforcing bars S are skeletonized (the virtual center lines of the reinforcing bars S are three-dimensionally shown). An example of the reinforcing bar arrangement model 764 in the case of the workpiece B shown in FIG. 4 is shown in FIG. 5. The reinforcing bar arrangement model 764 includes, for example, information on the number of reinforcing bars S arranged in each of the X, Y, and Z directions and position information of intersections P between the reinforcing bars S. In addition, it may include information such as the interval between the reinforcing bars S in each of the X, Y, and Z directions, and angle information when the reinforcing bar S is inclined. The reinforcing bar arrangement model 764 is an example of the intersection model according to the present disclosure, and it only needs to include at least arrangement information of a plurality of intersections P. Note that the data format of the reinforcing bar arrangement model 764 is not particularly limited, and it may be image data or numerical data of coordinates. Also, the storage unit 76 may record various data other than those described above that are acquired during the execution of the binding process described later at any time.

[0043] The control unit 77 is constituted by, for example, a CPU (Central Processing Unit) or the like, and controls the operations 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 or the like, develops a program previously stored in the storage unit 76, and executes various processes in cooperation with the developed program.

[0044] [Operation of the Binding System] Subsequently, the operation of the binding system 1 when executing a 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 to 12 are diagrams for explaining the binding process. Among these, FIG. 8 is a diagram showing an example of image data of an intersection P (target intersection Pa) acquired by the second camera 51, FIG. 9 is a diagram showing an example of image data with height information of the reinforcing bar S and other positions added to FIG. 8, and FIGS. 10 to 12 are diagrams for explaining the insertion operation of the binding machine 61 corresponding to the distance between the intersection P and its back surface D.

[0045] In the binding process, for example, multiple reinforcing bars S arranged in a grid pattern are bound together at the intersections P where the multiple reinforcing bars S intersect. This binding process is performed when the control unit 77 of the control device 7 reads the binding program 761 from the storage unit 76 and executes it. Here, it is assumed that the workpiece B is placed in the shooting area E1 with the workpiece B already placed on the holding stand 21 (see Figure 1). In the following, it is assumed that the control device 7 (or its control unit 77) is solely responsible for executing each step, but the control entity for the binding process is not particularly limited. For example, each component (or its control unit) of the binding system 1 may execute the process, or the control device 7 and each component may cooperate to execute the process.

[0046] As shown in Figure 6, when the bundling process is executed, the control unit 77 of the control device 7 first photographs the workpiece B in the shooting area E1 using the first camera 31 of the overall shooting unit 3 (STEP 1). Here, the control unit 77 acquires image data (monochrome image) in the XY plane, including distance information, for the entire workpiece B using 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 movement mechanism 32 to move the first camera 31 in the XY plane according to the size of the workpiece B and the field of view of the first camera 31, and photographs the entire workpiece B by dividing it into multiple parts (for example, 2x2 division into 4 parts in each XY direction) with some overlap. Then, the control unit 77 combines the acquired multiple images to generate an image of the entire workpiece B and stores it in the storage unit 76.

[0047] Next, the control unit 77 calculates the positions of all intersection points P included in the workpiece B based on the image data acquired in STEP 1 (STEP 2). Here, the control unit 77 calculates three-dimensional position information, including the X, Y, and Z coordinates, for each intersection point P. In this step, it is sufficient to calculate the positions of multiple intersection points P out of all the intersection points P present in the workpiece B. Alternatively, the position of each intersection point P may be calculated based on a rebar arrangement model 764 that models the arrangement of multiple intersection points P. In this case, the calculation of the position is easier because an intersection point P is considered to be one that matches the shape (arrangement) of the rebar arrangement model 764.

[0048] Next, the control unit 77 drives the drive motor 23 of the work holding unit 2 to operate the holding table 21, and moves the work B to the binding area E2 (STEP 3).

[0049] Next, the control unit 77 selects an intersection point P to be bound from among the plurality of intersection points P included in the work B (STEP 4). Here, for example, the control unit 77 selects any one intersection point P to be bound next from among the plurality of intersection points P excluding the intersection points P that have already been bound (recognized as such) based on a preset binding order. Hereinafter, the intersection point P selected as the next binding target by this selection is referred to as "target intersection point Pa".

[0050] Next, in the binding area E2, the control unit 77 causes the second camera 51 of the individual imaging unit 5 mounted on the robot arm 4 to approach the target intersection point Pa selected in STEP 4 (STEP 5). Here, the control unit 77 controls the operation of the robot arm 4 based on the position information of the target intersection point Pa calculated in STEP 2 and the movement amount of the work B in the X direction moved in STEP 3, and moves the second camera 51 directly above the target intersection point Pa. Then, the control unit 77 controls the operation of the lifting motor 52, lowers the second camera 51, and approaches it to a predetermined distance from the target intersection point Pa. As a result, the target intersection point Pa is positioned immediately in front of the downward-facing second camera 51, and for example, only the target intersection point Pa is within the viewing angle of the second camera 51 (the intersection points P other than the target intersection point Pa are outside the viewing angle).[[ID=?]]

[0051] 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. The second camera 51 observes a predetermined observation range within the vicinity of the target intersection Pa. As a result, as shown in Figure 8, for example, image data 762b 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.

[0052] 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).

[0053] 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 X and Y 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. Here, height information along the Z direction is also obtained based on the image data. In this case, the control unit 77 may determine the binding direction based on the position and orientation of the binding 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 for binding the target intersection Pa based on the diameters and intersection angles of the two reinforcing bars S that constitute the target intersection Pa.

[0054] Next, the control unit 77 performs an insertion feasibility determination to determine whether the binding machine 61 can be inserted into the target intersection Pa (STEP 8). Here, the feasibility of inserting the binding machine 61 into the target intersection Pa (approachability) is determined based on the image data acquired by the second camera 51 and the information of the binding machine 61. The following description will explain the case where the target intersection Pa is composed of two reinforcing bars S along the X and Y directions. Therefore, in the following explanation, "higher side (upper side)" means the side closer to the second camera 51 in the shooting direction of the second camera 51 (foreground side), or the side closer to the binding machine 61 in the insertion direction of the binding machine 61 (foreground side), and "lower side (lower side)" means the opposite side.

[0055] Specifically, in determining whether insertion is possible, as shown in Figure 7, the control unit 77 first sets a predetermined measurement range G1 that includes the center C of the target intersection Pa in the image data acquired in STEP 6 (STEP 81; Figure 9). Figure 9 is an example of image data 762c in which height information of the reinforcing bars S and other positions, including the target intersection Pa, is added to the image data 762b in Figure 8.

[0056] Next, the control unit 77 determines the highest maximum height (reinforcement height) Hr among the reinforcing bars S within the measurement range G1 (STEP 82). In the example in Figure 9, the position where the reinforcement height Hr is located is approximately equal to the center C of the target intersection Pa.

[0057] Next, the control unit 77 determines the highest height (back height) Hb of the back surface D of the reinforcing bar S within the measurement range G1 (STEP 83). Here, "back surface D" of the reinforcing bar S refers to the part other than the reinforcing bar S that is lower than the reinforcing bar S. In this step, the control unit 77 masks the intersection P portion of the measurement range G1 that includes the reinforcing bar S, creating a masked region G2, and then determines the height of the highest position among the remaining back surface D as the back height Hb.

[0058] Next, the control unit 77 compares the difference between the rebar height Hr and the back height Hb, "Hr-Hb," with the insertion length Hm of the tying machine 61 (STEP 84). Here, first, the control unit 77 calculates the difference between the rebar height Hr and the back height Hb, "Hr-Hb," as the distance between the target intersection Pa and the back D (first distance). The control unit 77 stores the calculated distance in the storage unit 76 in association with the target intersection Pa. Then, the control unit 77 compares the calculated Hr-Hb with the insertion length Hm of the tying machine 61. The insertion length Hm of the tying machine 61 is the maximum length of the insertion part 61T of the tying machine 61 that is inserted into the intersection P, along the insertion direction. For example, it is the distance in the Z direction between the bottom surface 61f of the space surrounding the rebar S during insertion (between the curl guide 613 and the guide guide 614) and the tip (lower end) of the curl guide 613 (see Figure 10). The value of the insertion length Hm is pre-stored in the binding information 765 of the storage unit 76.

[0059] In STEP 84, if the difference between the rebar height Hr and the back height Hb is greater than the insertion length Hm of the binding machine 61 (Hr - Hb > Hm), the control unit 77 determines that the target intersection Pa can be bound and inserts the insertion part 61T of the binding machine 61 to its innermost position, as shown in Figure 10 (STEP 85). Here, "greater than insertion length Hm" means that the difference Hr - Hb is greater than the insertion length Hm by a predetermined amount including various errors and margins. This means that the difference Hr - Hb is definitely greater than the insertion length Hm, and the binding machine 61 will not come into contact with the back surface D during insertion. Also, "inserting to the innermost position" is not particularly limited, but for example, it means inserting the insertion part 61T into the intersection P until the upper rebar S comes into contact with (or is just before contact with) the bottom surface 61f of the insertion part 61T.

[0060] In STEP 84, if the difference between the rebar height Hr and the back height Hb is less than or equal to the insertion length Hm of the binding machine 61 (Hr - Hb ≤ Hm), the control unit 77 determines that the target intersection Pa can be bound and inserts the insertion part 61T into the intersection P to a depth where it does not come into contact with the back surface D, as shown in Figure 11 (STEP 86). Here, "less than or equal to" the insertion length Hm means that the difference Hr - Hb is equal to or less than the insertion length Hm. This means that if the insertion part 61T of the binding machine 61 is inserted to its deepest point, there is a risk that the binding machine 61 will come into contact with the back surface D. However, in this step, the insertion part 61T may be determined to be uninsertable, and binding of the target intersection Pa (STEP 9 described later) may be omitted. Furthermore, as shown in Figure 12, if the difference Hr-Hb is close to the sum of the diameters of the multiple reinforcing bars S that form the intersection Pa (in the example in Figure 12, there are two reinforcing bars S, so Hr-Hb ≈ diameter of reinforcing bars S × 2), a wire path cannot be formed between the intersection Pa and the back surface D, so it may be determined that insertion is not possible and the binding of the target intersection Pa (STEP 9 described later) may be omitted.

[0061] In STEP 85 and S86, the control unit 77 controls the movement of the robot arm 4 and, instead of the second camera 51, moves the binding device 6 mounted on the end effector 43 closer to the target intersection Pa, and inserts the insertion part 61T of the binding machine 61 into the target intersection Pa. At this time, it is preferable for the control unit 77 to match the relative position of the binding machine 61 and the workpiece B to the direction in which the insertion distance of the binding machine 61 to the target intersection Pa is longer, among the insertion orientations of the binding machine 61 (insertion part 61T) in a plan view of the target intersection Pa. In other words, the orientation of the insertion part 61T (curl guide 613 and guidance guide 614) in a plan view is matched to the direction in which the insertion distance of the insertion part 61T (difference between difference Hr-Hb and insertion length Hm) is longer, for example, between the 2 o'clock direction L1 and the 10 o'clock direction L2 (see Figure 8). In this case, candidate insertion positions (2 o'clock direction L1, 10 o'clock direction L2) are pre-stored in the memory unit 76, and the control unit 77 selects one of these that has a longer insertion distance for the insertion unit 61T. At this time, the control unit 77 also controls the movement of the binding machine 61 so that the reinforcing bars S that constitute the target intersection Pa do not come into contact with the binding machine 61.

[0062] Next, as shown in Figure 6, 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 described above, this may be used as the amount of wire W used.

[0063] 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.

[0064] [Technical Effects of This Embodiment] As described above, according to this embodiment, the distance between the intersection point P and its back surface D (first distance) is calculated based on the information observed by the second camera 51, and it is determined whether or not the binding machine 61 can be inserted into the intersection point P based on this distance and the information of the binding machine 61. Therefore, it is possible to suitably determine whether or not the binding machine 61 can be inserted into the intersection point P. Consequently, the binding work can be performed safely without damaging the binding machine 61 by bringing it into contact with the back surface D.

[0065] Furthermore, according to this embodiment, the ability to insert the binding machine 61 is determined based on the insertion distance of the binding machine 61 in the insertion position of the binding machine 61, which is pre-stored in the memory unit 76. In other words, by making the determination in the actual insertion position, it is possible to more reliably determine whether or not binding is actually possible.

[0066] Furthermore, according to this embodiment, whether or not insertion is possible is determined based on the difference between the highest reinforcing bar height Hr among the reinforcing bars S and the highest back surface height Hb among the back surface D of the reinforcing bars S. In other words, in the insertion direction of the binding machine 61, whether or not insertion is possible is determined based on the distance between the frontmost intersection point P and the frontmost back surface D. This makes it possible to determine whether or not insertion is possible at the location with the shortest distance, using the front side (upper side) of the insertion direction as a reference. However, the positions of the intersection points and back surfaces used to determine the distance for determining whether or not insertion is possible are not limited to the frontmost positions in the insertion direction.

[0067] Furthermore, according to this embodiment, the relative position between the binding machine 61 and the workpiece B is controlled based on the information of the binding machine 61 stored in the memory unit 76 and the difference between the rebar height Hr and the back height Hb. This allows the angle between the intersection P and the binding machine 61 to be suitably changed for angles with greater depth. In other words, the angle of the binding machine 61 can be adjusted to achieve an appropriate insertion angle with respect to the intersection P.

[0068] Furthermore, according to this embodiment, the relative positions of the binding machine 61 and the workpiece B are aligned in the direction in which the insertion distance of the binding machine 61 to the intersection P is long. This allows the binding machine 61 to be inserted in an insertion position that has a long insertion distance and a low risk of contact between the binding machine 61 and the back surface D.

[0069] Furthermore, according to this embodiment, the distance between each of the multiple intersections P and the back surface D of that intersection P is stored in the storage unit 76. Therefore, if there is an intersection P that cannot be fastened, it is possible to determine whether the reason is due to the insertion depth or not based on the data in the storage unit 76.

[0070] Furthermore, according to this embodiment, based on the determination result regarding whether or not the binding machine 61 can be inserted into the intersection P, it is determined whether or not the intersection P can be bound with the binding machine 61. This allows for a favorable determination of whether or not binding is possible.

[0071] Furthermore, according to this embodiment, when Hr - Hb > Hm, the insertion part 61T of the binding machine 61 is inserted to its deepest point, and when Hr - Hb ≤ Hm, the insertion part 61T is inserted to a depth where it does not come into contact with the back surface D. In other words, the insertion distance of the binding machine 61 to the intersection P is controlled based on the calculation result of the distance between the intersection P and the back surface D. This allows the binding machine 61 to be moved to an appropriate height position according to the distance, and consequently enables strong binding according to the environment of each intersection P.

[0072] Furthermore, according to this embodiment, the intersection P and the binding machine 61 are controlled so as not to come into contact. As a result, neither the binding machine 61 nor the workpiece B is damaged.

[0073] Furthermore, according to this embodiment, the position of each intersection P is detected based on a rebar arrangement model 764 (intersection model) that models the arrangement of multiple intersections P. This makes it easier to detect the position of each intersection P. Also, because the position of each intersection P is determined based on the overall arrangement, the position of each intersection P can be detected appropriately even if the orientation of the workpiece B and the camera is slightly misaligned.

[0074] Furthermore, according to this embodiment, the second camera 51 observes a predetermined observation range within the vicinity of the intersection point P. This allows the observation range to be narrowed down to the necessary locations around the intersection point P, enabling efficient determination of whether insertion is possible or not.

[0075] [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.

[0076] Furthermore, in the bundling process of the above embodiment, the determination of whether or not STEP 8 can be inserted is performed based on the information observed (captured) by the second camera 51. However, the determination of whether or not insertion can be performed based on the information observed by the first camera 31. In other words, the observation unit according to this disclosure includes the first camera 31 and the second camera 51. Moreover, the observation unit according to this disclosure only needs to be capable of observing the workpiece (object to be bundled), 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] Furthermore, details shown in the above embodiments can be modified as appropriate without departing from the spirit of the invention.

[0083] 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.

[0084] This application is based on a Japanese patent application (Patent Application No. 2024-230954) filed on December 26, 2024, the contents of which are incorporated by reference within this application.

[0085] This disclosure has the effect of being able to suitably determine whether or not a binding portion can be inserted into an intersection, and is useful for binding devices and the like.

[0086] 1 Binding System (Binding Device) 7 Control Device 31 First Camera (Observation Unit) 51 Second Camera (Observation Unit) 61 Rebar Binding Machine (Binding Unit) 61T Insertion Unit 76 Memory Unit 77 Control Unit (Calculation Unit, Judgment Unit) 761 Binding Program 762, 762b, 762c Image Data 764 Rebar Arrangement Model (Intersection Model) 765 Binding Unit Information B Workpiece (Object to be Binded) D Back Side G1 Measurement Range G2 Mask Area Hr Rebar Height Hb Back Side Height L1 2 o'clock Direction (Insertion Position) L2 10 o'clock Direction (Insertion Position) P Intersection Pa Target Intersection S Rebar

Claims

1. A binding device comprising: a binding section capable of binding objects to be bound including an intersection; an observation section capable of observing the objects to be bound; a calculation section that calculates a first distance between the intersection and the back surface of the intersection based on information observed by the observation section; and a determination section that determines whether or not the binding section can be inserted into the intersection based on the first distance calculated by the calculation section and information about the binding section.

2. The binding device according to claim 1, comprising a storage unit that stores in advance the insertion position of the binding portion with respect to the intersection, wherein the calculation unit determines whether or not the binding portion can be inserted based on the insertion distance of the binding portion to the intersection in the insertion position.

3. The fastening device according to claim 1, wherein the calculation unit calculates the distance between the frontmost position of the intersections and the frontmost position of the back surface in the insertion direction of the fastening portion as the first distance.

4. The binding device according to claim 1, further comprising a storage unit for pre-storing information of the binding portion.

5. The binding device according to claim 4, further comprising a control unit that controls the relative position between the binding unit and the object to be bound based on the information of the binding unit stored in the storage unit and the first distance calculated by the calculation unit.

6. The binding device according to claim 5, wherein the control unit corresponds the relative position of the binding portion and the object to be bound to the orientation in which the insertion distance of the binding portion to the intersection is longer.

7. The bundling device according to claim 1, further comprising a storage unit for storing the distance between each of the plurality of intersections and the back surface of said intersection.

8. The binding device according to claim 1, wherein the determination unit determines whether or not the intersection can be bound with the binding unit based on the determination result regarding whether or not the binding unit can be inserted into the intersection.

9. The binding device according to claim 1, further comprising a control unit for controlling the relative position between the binding unit and the object to be bound, wherein the control unit controls the insertion distance of the binding unit into the intersection based on the calculation result of the calculation unit.

10. The binding device according to claim 9, wherein the control unit controls the intersection and the binding portion so that they do not come into contact.

11. The binding device according to claim 1, comprising a storage unit that pre-stores an intersection model which models an arrangement of a plurality of the intersections, and the determination unit that detects the position of the intersection based on the intersection model.

12. The bundling device according to claim 1, wherein the observation unit observes a predetermined observation range within the vicinity of the intersection.

13. A binding program that causes a computer to control a binding device comprising a binding unit capable of binding objects including an intersection point, and an observation unit capable of observing the objects to be bound, to function as: a calculation unit that calculates a first distance between the intersection point and the back surface of the intersection point based on information observed by the observation unit; and a determination unit that determines whether or not the binding unit can be inserted into the intersection point based on the first distance calculated by the calculation unit and information about the binding unit.

Images