Welding teaching system and welding teaching method

Abstract

This welding teaching system comprises: a teaching device operated by a worker, the teaching device acquiring position information of a workpiece to be welded; and a terminal device communicably connected to the teaching device, the terminal device constructing a robot model corresponding to a welding robot having a welding torch, and a workpiece model corresponding to the workpiece, in a virtual space. The terminal device calibrates a coordinate system between a real space and the virtual space on the basis of a coordinate system in an operation space of the teaching device. The teaching device acquires coordinate values of at least three points located on the workpiece through an acquisition operation performed by the worker and transmits the coordinate values to the terminal device. The terminal device corrects the workpiece model on the basis of the acquired coordinate values of the at least three points when it is assessed that the workpiece model needs to be corrected.

Description

Welding teaching system and welding teaching method

[0001] This disclosure relates to a welding teaching system and a welding teaching method.

[0002] Patent Document 1 discloses a welding system comprising a welding robot equipped with a torch and a welding robot control program creation device. The welding system acquires positional information of the welding start point and welding end point for welding a workpiece, and orientation information that can identify the orientation of the torch relative to the welding line at a welding teaching point on the welding line connecting the welding start point and the welding end point. Based on the positional information and orientation information, it creates a welding robot control program that performs welding from the welding start point to the welding end point, and performs welding on the workpiece based on the welding robot control program.

[0003] International Publication No. 2021 / 251087

[0004] This disclosure aims to provide a welding teaching system and a welding teaching method that more appropriately correct a workpiece model based on the positional information of a workpiece in real space, with reference to a coordinate system in the operating space of the teaching device.

[0005] This disclosure provides a welding teaching system comprising: a teaching device operated by an operator to acquire positional information of a workpiece to be welded; and a terminal device communicably connected to the teaching device and constructing a robot model corresponding to a welding robot having a welding torch and a workpiece model corresponding to the workpiece in a virtual space, wherein the terminal device performs calibration of the coordinate systems between the real space and the virtual space based on the coordinate system in the operating space of the teaching device; the teaching device acquires coordinate values ​​of at least three points located on the workpiece through acquisition operations by the operator and transmits them to the terminal device; and the terminal device corrects the workpiece model if it determines that correction of the workpiece model is necessary based on the acquired coordinate values ​​of at least three points.

[0006] Furthermore, this disclosure provides a welding teaching method performed by a system comprising: a teaching device operated by an operator to acquire positional information of a workpiece to be welded; and a terminal device communicably connected to the teaching device and constructing a robot model corresponding to a welding robot having a welding torch and a workpiece model corresponding to the workpiece in a virtual space, wherein the method includes calibrating the coordinate systems of the real space and the virtual space based on the coordinate system in the operating space of the teaching device, acquiring coordinate values ​​of at least three points located on the workpiece through acquisition operations by the operator, and correcting the workpiece model if it is determined that correction of the workpiece model is necessary based on the acquired coordinate values ​​of at least three points.

[0007] According to this disclosure, the work model can be more appropriately corrected based on the positional information of the work in real space, with reference to the coordinate system in the operating space of the teaching device.

[0008] Figures illustrating an example of a welding system according to an embodiment; Figure illustrating the coordinate system in the operating space of the teaching device; Figure illustrating the calibration of the coordinate system between real space and virtual space; Figure illustrating the correction process of the work model; Figure illustrating the position correction of the work model in a virtual space; Figure illustrating the attitude correction of the work model in a virtual space; Figure illustrating the dimensional correction of the work model in a virtual space; Figure illustrating the shape measurement of the work model and the construction process of the work model; Figure illustrating the 3D model generation process of the work model and an example of the construction process of the work model; Figure illustrating the 3D model generation process of the work model and an example of the construction process of the work model; Figure corresponding to Figure 7 when the work is cylindrical; Flowchart showing an example of the operation procedure of terminal device P1 in the embodiment; Figure showing an example of an operation log display image when there is a problem with the simulation result.

[0009] (Background to this Disclosure) In recent years, there has been a teaching method that uses Virtual Reality (VR) equipment to teach welding operations. Compared to using general offline teaching systems such as teach pendants, this method allows the operator to directly teach the teaching points, thus reducing the time required to teach the teaching points. In such welding operation teaching methods, since the operation is taught by the operator's manual operation, it is necessary to verify whether the robot actually operates as requested by the operator, or whether the robot interferes with the workpiece. However, when performing verification by operating the robot in real space, the operator has to move the welding torch sequentially to the taught teaching points and check whether it interferes with the workpiece, which takes time. In addition, if the robot interferes with the workpiece, there is a possibility that the robot will be damaged. For this reason, verification is sometimes performed by simulation in a virtual space when teaching welding operations. However, in real space, design errors are likely to occur due to factors such as the machining accuracy of the jig or the mounting angle of the robot, and discrepancies can occur between real space and virtual space, particularly regarding the positional relationship between the robot and the workpiece.

[0010] Therefore, we will describe a welding teaching system and a welding teaching method that appropriately correct the workpiece model based on the positional information of the workpiece in real space, with reference to the coordinate system in the operating space of the teaching device.

[0011] The following describes in detail embodiments of the welding teaching system and welding teaching method disclosed herein, with reference to the drawings as appropriate. However, unnecessary details may be omitted. For example, detailed explanations of already well-known matters and redundant explanations of substantially identical configurations may be omitted. This is to avoid the following explanation becoming unnecessarily verbose and to facilitate understanding by those skilled in the art. The accompanying drawings and the following explanation are provided to enable those skilled in the art to fully understand this disclosure and are not intended to limit the subject matter described in the claims.

[0012] <Overview of the Welding System> First, the welding system 100 according to the embodiment will be described with reference to Figure 1. Figure 1 is a diagram showing an example of the welding system 100 according to the embodiment. Note that the configurations of the welding system 100, welding teaching system 200, and welding robot system 300 shown in Figure 1 are examples and are not limited thereto.

[0013] The welding system 100 includes a welding teaching system 200 for teaching welding operations to the welding robot 1, and a welding robot system 300 for the welding robot 1 to perform welding operations.

[0014] The welding teaching system 200 generates a welding teaching program to cause the welding robot 1 to perform welding operations based on teaching points taught by the operator teaching the welding operations, and transmits it to the welding robot system 300. The welding teaching system 200 includes at least one base station BS, a controller CTR, a head-mounted display HMD, and a terminal device P1.

[0015] The base station BS is connected to the controller CTR and the terminal device P1 so that data communication is possible between them. The base station BS emits infrared light toward the controller CTR in order to detect the position information and attitude information of the controller CTR at the controller CTR's operating position.

[0016] The controller CTR is connected to the head-mounted display HMD, base station BS, and terminal device P1 so as to be able to communicate data. The controller CTR is equipped with at least one operation button (not shown) that can accept operations from the operator, and based on the operation of pressing the operation button (not shown), it accepts an acquisition operation to acquire position information of the workpiece Wk to be welded, and a teaching operation (input operation) to teach teaching points. The operator teaches teaching points to the actual workpiece Wk by gripping and operating the controller CTR as if it were a welding torch 2 while looking at the teaching screen described later. The controller CTR may be equipped with a tip that has the same shape as the welding torch 2 so that the operator can intuitively teach the teaching points that the welding torch 2 of the welding robot 1 will pass through using the controller CTR.

[0017] Furthermore, the controller CTR includes at least one light-receiving unit (not shown) capable of receiving infrared light emitted from the base station BS. Based on the arrival time or angle information of the infrared light received by the light-receiving unit (not shown), the controller CTR calculates the position information of the tip of the controller CTR and the attitude information of the controller CTR at the time the operation button is pressed. The controller CTR transmits the calculated position information of the tip of the controller CTR and the attitude information of the controller CTR to the terminal device P1.

[0018] Furthermore, the calculation of the position information of the tip of the controller CTR, or the attitude information of the controller CTR, may be performed by a head-mounted display (HMD) or terminal device P1.

[0019] The head-mounted display (HMD) is connected to the controller (CTR) and the terminal device (P1) in a way that enables data communication between them, and functions as a device for relaying the communicated data. The head-mounted display (HMD) is not mandatory and may be omitted; in such cases, data communication between the controller (CTR) and the terminal device (P1) will occur directly. Furthermore, the head-mounted display (HMD) does not need to be worn on the worker's head; it can be installed in any location that enables data communication between the controller (CTR) and the terminal device (P1).

[0020] Terminal device P1 is connected to the base station BS, controller CTR, head-mounted display HMD, and robot control device 3, respectively, so as to enable data communication between them. Based on the position information and orientation information of the teaching points taught by the controller CTR, terminal device P1 generates a welding teaching program to cause the welding robot 1 to perform welding. Terminal device P1 constructs a robot model corresponding to the welding robot 1 and a work model corresponding to the workpiece Wk in a virtual space, and performs a simulation in the virtual space based on the welding teaching program. Terminal device P1 includes a communication unit 10, a processor 11, a memory 12, an input unit 13, and a display unit 14.

[0021] The communication unit 10 is connected to the base station BS, controller CTR, head-mounted display HMD, and robot control device 3 via wireless or wired communication to perform data transmission and reception. The communication unit 10 outputs various data transmitted from the base station BS, controller CTR, head-mounted display HMD, and robot control device 3 to the processor 11. The communication unit 10 transmits the various data output from the processor 11 to the corresponding device (base station BS, controller CTR, head-mounted display HMD, or robot control device 3). Wireless communication here refers to communication via a wireless Local Area Network (LAN) such as Wi-Fi®.

[0022] The processor 11 is configured using, for example, a Central Processing Unit (hereinafter referred to as "CPU") or a Field Programmable Gate Array (hereinafter referred to as "FPGA"), and works in cooperation with the memory 12 to perform various processes and controls. Specifically, the processor 11 refers to the programs and data held in the memory 12 and executes those programs to realize various functions for generating welding teaching programs.

[0023] Memory 12 includes, for example, Random Access Memory (hereinafter referred to as "RAM"), which is used as work memory when executing each process of the processor 11, and Read Only Memory (hereinafter referred to as "ROM"), which stores programs and data that define the operation of each of the processors 11. Data or information generated or acquired by the processor 11 is temporarily stored in RAM. Programs that define the operation of the processor 11 are written in ROM. Memory 12 may record various data related to the virtual space, various programs or data necessary for generating the welding teaching program. For example, memory 12 records location information of the workpiece Wk, information related to production equipment for the workpiece Wk such as the welding robot 1, welding torch 2 or jig, a robot model, a workpiece model, a 3D model of the workpiece Wk, etc.

[0024] The input unit 13 is a user interface capable of receiving input operations from an operator, and can be implemented by, for example, a keyboard, mouse, or touch panel. The operator operating the input unit 13 does not necessarily have to be the same person as the operator operating the controller CTR. The input unit 13 converts the received input operations into electrical signals and transmits them to the processor 11. If the input unit 13 is implemented by a touch panel, it may be integrated with the display unit 14.

[0025] The display unit 14 is configured using, for example, a Liquid Crystal Display (LCD) or an Organic Electroluminescence (EL). The display unit 14 displays image data output from the processor 11.

[0026] The welding robot system 300 is configured to drive a welding robot 1 capable of performing welding, and drives the welding robot 1 based on a welding teaching program transmitted from a terminal device P1. The welding robot system 300 includes the welding robot 1, a robot control device 3, and a teach pendant TP. The teach pendant TP is not an essential component and may be omitted.

[0027] The welding robot 1 is connected to the robot control device 3 for data communication. The welding robot 1 has a multi-joint robot arm, and a welding torch 2 is provided as an end effector at the tip of the robot arm. Under the control of the corresponding robot control device 3, the welding robot 1 drives the welding torch 2 and performs welding operations based on a welding teaching program.

[0028] The robot control device 3 is connected to the welding robot 1, the teach pendant TP, and the terminal device P1 so that data communication is possible between them. Based on the welding teaching program transmitted from the terminal device P1, the robot control device 3 controls the welding robot 1 to perform welding operations. The robot control device 3 may also read and transmit welding operation programs based on a control command that requests the readout of a welding operation program from the teach pendant TP. Furthermore, the robot control device 3 may acquire and record modified or changed welding operation programs from the teach pendant TP.

[0029] The teach pendant TP is connected to the robot control device 3 in a manner that enables data transmission and reception. The teach pendant TP modifies or changes the welding teaching program recorded in the robot control device 3 and transmits it to the robot control device 3.

[0030] <Calibration of Coordinate Systems between Real Space and Virtual Space>Next, referring to FIGS. 2A and 2B, the calibration of the coordinate systems between the real space and the virtual space will be described. FIG. 2A is a diagram for explaining the coordinate system in the operation space CS of the teaching device (controller CTR). FIG. 2B is a diagram for explaining the calibration of the coordinate systems between the real space and the virtual space.

[0031] The coordinate system (also referred to as the "operation space coordinate system O ｒ ,

[0032] , ") in the operation space CS of the teaching device (controller CTR) is a three-dimensional coordinate system that defines the position information and orientation information of the controller CTR at the operation position of the controller CTR operated by the operator, and is a three-dimensional coordinate system of the real space detectable by the base station BS (see FIG. 2A). The operation space coordinate system O ｔ is, for example, e ｘｔ axis and e ｙｔ axis define the horizontal direction, and the e ｚｔ axis perpendicular to this horizontal direction defines the vertical direction. The position of the welding robot 1 in the real space, the state (position, orientation, and dimensions, etc.) of the workpiece Wk in the real space, the position of the robot model in the virtual space, and the state (position, orientation, and dimensions, etc.) of the workpiece model in the virtual space are defined based on the operation space coordinate system O ｔ .

[0032] The calibration of the coordinate systems between the real space and the virtual space can be realized, for example, by the following method. First, the operator uses a teach pendant TP or the like to control the welding robot 1 and teaches each of the three teaching points in order to adjust the position of the robot model in the virtual space. The terminal device P1 defines the first coordinate system O ｒ based on each of the three teaching points taught by the welding robot 1 (see FIG. 2B). The three teaching points mentioned here are the origin of the first coordinate system O ｒ , the point defining the e ｘｒ axis direction with respect to the origin, and the point defining the e ｙｒ axis direction with respect to the origin.

[0033] Next, the operator operates the controller CTR to teach each of the three teaching points described above within the operation space CS. At this time, the base station BS acquires the position information (coordinate values) of the controller CTR at each teaching point. The terminal device P1 adjusts the first coordinate system O ｒ based on the position information (coordinate values) of the controller CTR at each teaching point acquired by the base station BS.

[0034] Here, the positional relationship between the coordinate system of the welding robot 1 and the first coordinate system O ｒ is known. Therefore, as described above, the calibration of the coordinate systems of the real space and the virtual space by the terminal device P1 is completed. That is, the position of the robot model in the virtual space is adjusted. Note that the calibration of the coordinate systems of the real space and the virtual space is not limited to the method described above, and other known methods may be adopted.

[0035] <Next, referring to FIGS. 3 to 6, the correction process of the work model will be described. FIG. 3 is a diagram for explaining the correction process of the work model. FIG. 4 shows the virtual space and is a diagram for explaining the position correction of the work model Wk. FIG. 5 shows the virtual space and is a diagram for explaining the posture correction of the work model Wk. FIG. 6 shows the virtual space and is a diagram for explaining the dimensional correction of the work model Wk.

[0036] In the description here, it is assumed that the work model has already been constructed on the virtual space. Also, in FIGS. 4 to 6, for the sake of easy understanding of the explanation, the work Wk is illustrated by a dotted line.

[0037] As shown in FIG. 3, the operator operates the controller CTR to acquire the coordinate values of at least three points (reference numerals AP1 to AP3) located on the work Wk. Note that three points are sufficient for the number of coordinate values to be acquired, but if the number is large, the calculation accuracy of the difference in the mode of the work model WkM with respect to the mode of the work Wk (see below) is improved.

[0038] In the illustrated example, the operator presses an operation button (not shown) while the tip of the controller CTR is placed against each of the three corners of a predetermined plane of the workpiece Wk. The controller CTR transmits the position information (coordinate values) of the tip of the controller CTR at the time the operation button (not shown) is pressed to the terminal device P1.

[0039] The processor 11 of the terminal device P1 calculates the difference in the configuration of the workpiece model WkM (see Figure 4, etc.) with respect to the configuration of the workpiece Wk, based on the coordinate values ​​of at least three points transmitted from the controller CTR. The difference in configuration here refers to at least one of positional deviation, orientation deviation, and dimensional deviation.

[0040] Then, the processor 11 of the terminal device P1 determines whether or not correction of the work model WkM is necessary based on the calculated difference, and if it determines that correction is necessary, it corrects the work model WkM. This ensures that the real space and the virtual space are aligned. Note that the correction of the work model WkM here includes at least one of position correction, orientation correction, and dimensional correction.

[0041] For example, as shown in Figure 4, if the work model WkM is misaligned, the terminal device P1 corrects the position of the work model WkM so that the coordinate values ​​of three points (symbols APM1 to APM3) located on the work model WkM match the coordinate values ​​of three points (symbols AP1 to AP3) located on the work Wk.

[0042] For example, as shown in Figure 5, if the work model WkM is misaligned, the terminal device P1 corrects the orientation of the work model WkM so that the coordinate values ​​of three points (symbols APM1 to APM3) located on the work model WkM match the coordinate values ​​of three points (symbols AP1 to AP3) located on the work Wk.

[0043] For example, as shown in Figure 6, if the work model WkM is dimensionally misaligned, the terminal device P1 corrects the dimensions of the work model WkM so that the coordinate values ​​of three points (symbols APM1 to APM3) located on the work model WkM match the coordinate values ​​of three points (symbols AP1 to AP3) located on the work Wk.

[0044] Furthermore, when correcting the work model WkM, the head-mounted display (HMD) may generate and display an image in which the work model WkM is superimposed on an image captured by the head-mounted display (HMD) camera (not shown). The image captured by the head-mounted display (HMD) camera (not shown) is the space related to the welding operation of the welding robot 1, including the workpiece Wk. In other words, the operator can intuitively confirm the difference between the appearance of the work model WkM and the appearance of the workpiece Wk by looking at whether or not the work model WkM is superimposed on the workpiece Wk.

[0045] Therefore, the correction may be performed by an operator wearing a head-mounted display (HMD), or it may be performed by comparing, for example, the feature points of the workpiece Wk with the feature points of the workpiece model WkM using a head-mounted display (HMD).

[0046] <Work Model Construction Process> Next, the work model construction process will be explained with reference to Figures 7 to 9. Figure 7 shows the shape measurement of work Wk and is a diagram illustrating the work model construction process. Figure 8A shows the 3D model generation process of work Wk and is a diagram illustrating an example of the work model construction process. Figure 8B shows the 3D model generation process of work Wk and is a diagram illustrating an example of the work model construction process. Figure 9 is a diagram corresponding to Figure 7 when work Wk is cylindrical.

[0047] In this explanation, it is assumed that no work model is constructed in the virtual space. However, if a 3D model of work Wk is recorded in the memory 12 of terminal device P1, the processor 11 of terminal device P1 can construct a work model in the virtual space based on the 3D model of work Wk by a known method. However, if a 3D model of work Wk is not recorded in the memory 12 of terminal device P1, the processor 11 of terminal device P1 can generate a 3D model of work Wk by, for example, the method described later. Even if a 3D model of work Wk is recorded in the memory 12 of terminal device P1, the method described later may also be used.

[0048] As shown in Figure 7, the operator operates the controller CTR to acquire multiple generation points GP along the outline of the workpiece Wk, and the coordinate values ​​of each of the multiple generation points GP. Preferably, the generation points GP here are the corners of each plane of the workpiece Wk.

[0049] In the example shown in Figure 8A, the operator presses an operation button (not shown) while the tip of the controller CTR is placed against each corner of each plane of the workpiece Wk. In the example shown in Figure 8B, the operator presses an operation button (not shown) while the tip of the controller CTR is placed against each corner of a predetermined plane of the workpiece Wk, and then presses an operation button (not shown) while the tip of the controller CTR is placed against each corner corresponding to the thickness of the workpiece Wk. The controller CTR transmits the position information (coordinate values) of the tip of the controller CTR at the time the operation button (not shown) is pressed to the terminal device P1.

[0050] In the example shown in Figure 8A, the processor 11 of the terminal device P1 generates polygons based on multiple generation points GP transmitted from the controller CTR and the coordinate values ​​of each generation point GP, and then combines the generated polygons. In the example shown in Figure 8B, the processor 11 of the terminal device P1 generates polygons of a predetermined plane based on multiple generation points GP transmitted from the controller CTR and the coordinate values ​​of each generation point GP, then generates polygons in the thickness direction of the workpiece Wk, and then combines the generated polygons. This generates a 3D model of the workpiece Wk. Subsequently, the terminal device P1 constructs a work model in virtual space based on the 3D model of the workpiece Wk using a known method. The characteristics (position, orientation, dimensions, etc.) of the constructed work model correspond to the characteristics (position, orientation, dimensions, etc.) of the workpiece Wk.

[0051] For example, as shown in Figure 9, if the workpiece Wk is cylindrical, the operator can operate the controller CTR to acquire three points on the circumference of the workpiece Wk and two points along the axial length, allowing the processor 11 of the terminal device P1 to generate a 3D model of the workpiece Wk.

[0052] <Example of Terminal Device Operation Procedure> Next, an example of the operation procedure for terminal device P1 will be described with reference to Figure 10. Figure 10 is a flowchart showing an example of the operation procedure for terminal device P1 in the embodiment.

[0053] The processor 11 operates in the coordinate system O ｔ Based on this, the coordinate system calibration between the real space and the virtual space is performed (St11). It is assumed that the processor 11 has already constructed a robot model corresponding to the welding robot 1 in the virtual space.

[0054] The processor 11 determines whether or not a work model WkM has been constructed in the virtual space (St12). If the 3D model of work Wk is stored in memory 12, the processor 11 assumes that the work model WkM has been pre-constructed in the virtual space based on the 3D model of work Wk.

[0055] If, in the processing of step St12, the processor 11 determines that a work model WkM has been constructed in the virtual space (St12, YES), it reads the coordinate values ​​of at least three points on the work Wk transmitted from the controller CTR (St13).

[0056] The processor 11 calculates the difference between the configuration of the work model WkM and the configuration of the work model WkM based on the coordinate values ​​of at least three points on the read work Wk (St14).

[0057] The processor 11 determines whether or not correction of the work model WkM is necessary based on the calculated difference (St 15). If there is a difference, correction of the work model WkM is necessary; if there is no difference, correction of the work model WkM is not necessary.

[0058] If the processor 11 determines in step St15 that correction of the work model WkM is necessary (St15, YES), it executes a correction process for the work model WkM (St16). The processor 11 may also transmit information about the work model WkM (e.g., its characteristics) to the head-mounted display (HMD) during step St16. In this case, the operator can confirm the correction result of the work model WkM via the head-mounted display (HMD).

[0059] The processor 11 executes the process of generating a welding teaching program (St17). The welding teaching program generation process can employ known methods. For example, the welding teaching program is generated based on information obtained through teaching operations performed by an operator using a teach pendant TP.

[0060] The processor 11 executes a simulation in a virtual space based on the generated welding teaching program (St18). This simulation operates the robot model based on the welding teaching program and is performed to verify the welding operation, for example, whether the robot model interferes with the workpiece model.

[0061] The processor 11 displays the simulation results performed in step St18 on the display unit 14 (St19). For example, if there are no problems with the simulation results, it may display a message to that effect. Alternatively, if there are problems with the simulation results, it may display the operation log display image DI as shown in Figure 11. In the example shown in Figure 11, it is shown that the robot model interfered with the workpiece model WkM when moving from a predetermined point P003 to a predetermined point P004, and when moving from a predetermined point P004 to a predetermined point P005. If there are problems with the simulation results in this way, the processor 11 may proceed to step St17 and execute the welding teaching program generation process again. Figure 11 is a diagram showing an example of the operation log display image DI when there are problems with the simulation results.

[0062] If, in the processing of step St12, the processor 11 determines that the work model WkM has not been constructed in the virtual space (St12, NO), it reads multiple generation points GP along the outline of the work Wk and their coordinate values ​​transmitted from the controller CTR (St20).

[0063] The processor 11 executes the process of constructing a work model WkM based on multiple generation points GP along the outline of the read work Wk and their coordinate values ​​(St21), and then proceeds to step St17. The configuration of the constructed work model WkM corresponds to the configuration of the work Wk.

[0064] If the processor 11 determines that correction of the work model WkM is unnecessary during the processing of step St15 (St15, No), it proceeds to step St17.

[0065] If the processor 11 determines, based on the above operating procedure, that there are no problems with the welding operation of the welding robot 1, it transmits a welding teaching program related to the determined welding operation to the robot control device 3. Alternatively, the processor 11 may determine whether or not there are problems with the welding operation of the welding robot 1 based on the simulation results.

[0066] As described above, the welding teaching system 200 in the embodiment uses a coordinate system in the operating space CS of the teaching device (controller CTR), i.e., the operating space coordinate system O ｔ The work model can be appropriately corrected to correspond to the characteristics of the workpiece Wk based on this reference. This improves the accuracy of simulations in the virtual space and prevents situations such as the welding robot 1 interfering with the workpiece Wk, for example, the welding torch 2, when the welding robot 1 is driven.

[0067] <Note> The following technologies are disclosed based on the descriptions of each embodiment above.

[0068] (Technology 1) A welding teaching system 200 comprising: a teaching device (controller CTR) operated by an operator to acquire positional information of a workpiece Wk to be welded; and a terminal device P1 that is communicably connected to the teaching device (controller CTR) and constructs a robot model corresponding to a welding robot 1 having a welding torch 2 and a workpiece model corresponding to the workpiece Wk in a virtual space, wherein the terminal device P1 is the coordinate system (operation space coordinate system O) in the operating space of the teaching device (controller CTR). ｔ A welding teaching system 200, which performs a calibration of the coordinate systems between the real space and the virtual space based on the following: The teaching device (controller CTR) acquires the coordinate values ​​of at least three points (AP1 to AP3) located on the workpiece Wk through an acquisition operation by the operator and transmits them to the terminal device P1; and the terminal device P1, based on the acquired coordinate values ​​of at least three points (AP1 to AP3), corrects the workpiece model if it determines that correction of the workpiece model is necessary.

[0069] With this configuration, the welding teaching system 200 uses a coordinate system (operating space coordinate system O) in the operating space CS of the teaching device (controller CTR). ｔ Based on this, the position of the welding robot 1 in real space, the position of the robot model in virtual space, the position and orientation of the workpiece Wk in real space, and the position and orientation of the workpiece model in virtual space are defined. Then, the welding teaching system 200 determines that correction of the workpiece model is necessary based on the coordinate values ​​of at least three points (AP1 to AP3) located on the workpiece Wk, and corrects the workpiece model so that the coordinate system in the operating space CS of the teaching device (controller CTR) (operating space coordinate system O ｔ The work model can be more appropriately corrected to correspond to the characteristics of the workpiece Wk, based on the above.

[0070] (Technical 2) The teaching device (controller CTR) acquires a plurality of generation points GP along the outline of the workpiece Wk and the coordinate values ​​of each of the plurality of generation points GP by acquisition operations performed by the operator, and transmits them to the terminal device P1, and the terminal device P1 constructs the workpiece model in the virtual space based on the acquired plurality of generation points GP and the coordinate values ​​of each of the plurality of generation points GP, the welding teaching system 200 as described in (Technical 1).

[0071] With this configuration, the welding teaching system 200 uses a coordinate system (operating space coordinate system O) in the operating space CS of the teaching device (controller CTR). ｔ A work model can be constructed to correspond to the characteristics of the work Wk based on the above.

[0072] (Technical 3) The terminal device P1 performs at least one of position correction, orientation correction, and dimensional correction as correction of the work model, as a welding teaching system 200 according to (Technical 1) or (Technical 2).

[0073] This configuration allows the welding teaching system 200 to eliminate the differences between the workpiece Wk and the workpiece model.

[0074] (Technology 4) A welding teaching system 200 according to any one of (Technology 1) to (Technology 3), further comprising an XR device (head-mounted display HMD) for imaging the workpiece Wk, wherein the XR device (head-mounted display HMD) displays the workpiece model superimposed on the image of the workpiece Wk.

[0075] This configuration allows the welding teaching system 200 to provide real-time visual feedback to the operator, thereby improving work efficiency.

[0076] (Technical 5) The teaching device (controller CTR) receives a teaching operation for teaching the operation of the welding torch 2, and is a welding teaching system 200 according to any one of (Technical 1) to (Technical 4).

[0077] This configuration improves the positional accuracy of the teaching points acquired through the teaching operation in the welding teaching system 200, and enables the efficient generation of welding teaching programs.

[0078] (Technical 6) The terminal device P1 simulates the operation of the welding torch 2 taught by the teaching operation in the virtual space, as described in (Technical 5), welding teaching system 200.

[0079] This configuration improves the accuracy of simulations in the virtual space for the welding teaching system 200, and prevents situations such as a part of the welding robot 1, such as the welding torch 2, interfering with the workpiece Wk when the welding robot 1 is driven.

[0080] (Technical 7) A welding teaching method performed by a system (welding teaching system 200) comprising: a teaching device (controller CTR) operated by an operator to acquire positional information of a workpiece Wk to be welded; and a terminal device P1 that is communicably connected to the teaching device (controller CTR) and constructs a robot model corresponding to a welding robot 1 having a welding torch 2 and a workpiece model corresponding to the workpiece Wk in a virtual space, wherein the coordinate system in the operating space CS of the teaching device (controller CTR) is the operating space coordinate system O ｔ A welding teaching method comprising: calibrating the coordinate systems of the real space and the virtual space based on the above; obtaining coordinate values ​​of at least three points (AP1 to AP3) located on the workpiece Wk through acquisition operations by the operator; and correcting the workpiece model if it is determined that correction of the workpiece model is necessary based on the obtained coordinate values ​​of at least three points (AP1 to AP3).

[0081] With this configuration, the welding teaching system 200 uses a coordinate system (operating space coordinate system O) in the operating space CS of the teaching device (controller CTR). ｔBased on this, the position of the welding robot 1 in real space, the position of the robot model in virtual space, the position and orientation of the workpiece Wk in real space, and the position and orientation of the workpiece model in virtual space are defined. Then, the welding teaching system 200 determines that correction of the workpiece model is necessary based on the coordinate values ​​of at least three points (AP1 to AP3) located on the workpiece Wk, and corrects the workpiece model so that the coordinate system in the operating space CS of the teaching device (controller CTR) (operating space coordinate system O ｔ The work model can be more appropriately corrected to correspond to the characteristics of the workpiece Wk, based on the above.

[0082] The welding teaching system and welding teaching method described above have been explained with reference to the drawings, but it goes without saying that the disclosure is not limited to such examples. It is clear to those skilled in the art that various modifications, alterations, substitutions, additions, deletions, and equivalents can be conceived within the scope of the claims, and these are also understood to fall within the technical scope of the disclosure. Furthermore, the components of the various embodiments described above can be arbitrarily combined without departing from the spirit of the invention.

[0083] This disclosure is useful as a welding teaching system and welding teaching method that more appropriately corrects a workpiece model based on the positional information of a workpiece in real space, with reference to a coordinate system in the operating space of the teaching device.

[0084] 1 Welding robot 2 Welding torch 3 Robot control unit 10 Communication unit 11 Processor 12 Memory 13 Input unit 14 Display unit BS Base station CS Operating space DI Display image P1 Terminal device TP Teach pendant Wk Work HMD Head-mounted display 100 Welding system 200 Welding teaching system 300 Welding robot system

Claims

1. A welding teaching system comprising: a teaching device operated by an operator to acquire positional information of a workpiece to be welded; and a terminal device communicately connected to the teaching device and constructing a robot model corresponding to a welding robot having a welding torch and a workpiece model corresponding to the workpiece in a virtual space, wherein the terminal device performs calibration of the coordinate systems of the real space and the virtual space based on the coordinate system in the operating space of the teaching device; the teaching device acquires coordinate values ​​of at least three points located on the workpiece through acquisition operations by the operator and transmits them to the terminal device; and the terminal device corrects the workpiece model if it determines that correction of the workpiece model is necessary based on the acquired coordinate values ​​of at least three points.

2. The welding teaching system according to claim 1, wherein the teaching device acquires a plurality of generation points and the coordinate values ​​of each of the plurality of generation points along the outline of the workpiece by an acquisition operation performed by the operator, and transmits them to the terminal device, and the terminal device constructs the workpiece model in the virtual space based on the acquired plurality of generation points and the coordinate values ​​of each of the plurality of generation points.

3. The welding teaching system according to claim 1, wherein the terminal device performs at least one of position correction, orientation correction, and dimensional correction as correction of the work model.

4. The welding teaching system according to claim 1, further comprising an XR device for imaging the workpiece, wherein the XR device displays the workpiece model superimposed on the image of the workpiece.

5. The welding teaching system according to claim 1, wherein the teaching device receives a teaching operation for teaching the operation of the welding torch.

6. The welding teaching system according to claim 5, wherein the terminal device simulates the operation of the welding torch taught by the teaching operation in the virtual space.

7. A welding teaching method performed by a system comprising: a teaching device operated by an operator to acquire positional information of a workpiece to be welded; and a terminal device communicably connected to the teaching device to construct a robot model corresponding to a welding robot having a welding torch and a workpiece model corresponding to the workpiece in a virtual space, the method comprising: calibrating the coordinate systems of the real space and the virtual space based on the coordinate system in the operating space of the teaching device; acquiring coordinate values ​​of at least three points located on the workpiece through acquisition operations by the operator; and correcting the workpiece model if it is determined that correction of the workpiece model is necessary based on the acquired coordinate values ​​of at least three points.

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