The present disclosure relates to a picking device that picks and sorts a specific workpiece by a robot from a plurality of types of workpieces that are sorting objects to be transported.
In recent years, in various industries in the world, a picking device, which picks and sorts a specific component by a robot from a plurality of types of components that are sorting objects, is often used. For example, in a field of home appliance recycling, from a disassembled product or a crushed product, which is no longer needed and is disassembled or roughly crushed to a size of a component, a specific component is recognized and picked to be sorted and recovered for recycling.
As a conventional picking device, for example, there is a device disclosed in Japanese Patent No. 5464176.
In
On the other hand, as another picking device, for example, there is a device disclosed in Japanese Patent No. 5837065.
In
According to one aspect of the present disclosure, there is provided a picking device that selectively picks up a specific workpiece from a plurality of workpieces which are disassembled products or crushed products of goods, the picking device including: a transporter that transports the workpieces in a transport direction that is one direction at a transport speed; an imaging device that is disposed above the transporter and acquires three-dimensional information of each of the plurality of workpieces by imaging each of the plurality of workpieces; an object detector that detects that the workpiece to be transported has passed through a specific position of the transporter; a movement amount detection device that measures a workpiece movement amount of the workpiece by the transporter after the object detector detects that the workpiece has passed the specific position, and issues a measurement signal indicating the measured workpiece movement amount of each of the plurality of workpieces; a movement mechanism that moves the imaging device in the transport direction in synchronization with the transport speed of the transporter based on the measurement signal from the movement amount detection device; an imaging processor that performs image processing based on the information acquired by imaging by the imaging device and generates information necessary for selectively picking up the specific workpiece from the plurality of workpieces; a robot that holds the specific workpiece from the workpieces and moves the held specific workpiece to a predetermined position based on the necessary information acquired by the imaging processor for sorting; and a controller that controls a movement of the imaging device by the movement mechanism based on the transport speed of the transporter and the measurement signal from the movement amount detection device, and controls an operation of the robot based on the transport speed of the transporter, the measurement signal from the movement amount detection device, and the necessary information for sorting acquired by the imaging processor, in which the controller controls the movement of the imaging device by the movement mechanism, and the controller causes the robot to hold the specific workpiece to move to the predetermined position to perform sorting the plurality of workpieces.
In the configuration of Japanese Patent No. 5464176, since a two-dimensional imaging device is provided, it is not possible to obtain information on a three-dimensional outer shape, a position, and a posture.
On the other hand, in the configuration of Japanese Patent No. 5837065, three-dimensional information can be obtained, but only a stationary workpiece can be imaged.
In general, a three-dimensional imaging device takes time to capture an image, so that an accurate image cannot be acquired because a movement object blurs when the moving workpiece is imaged.
As described above, the conventional example has a problem that the three-dimensional imaging device cannot acquire the three-dimensional information such as the three-dimensional outer shape, the position, and the posture of the workpiece being transported without the movement object blur.
The present disclosure is given for solving the above-described conventional problems, and an object thereof is to provide a picking device capable of acquiring three-dimensional information of a workpiece without movement object blur by using a three-dimensional imaging device even for a moving workpiece.
Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings.
The picking device includes transporter 1, imaging device 5, object detector 3, movement amount detection device 4, movement mechanism 8, robot 6, imaging processor 51, and controller 52, and extracts and sorts specific workpiece 2a from a plurality of workpieces 2 which are disassembled products or crushed products of goods.
In the present specification, a plurality of workpieces 2 of which position coordinates (that is, X coordinates in
Transporter 1 transports the plurality of workpieces 2 in the transport direction that is one direction, for example, at a constant transport speed. In
Imaging device 5 is disposed above transporter 1, can be reciprocated by movement mechanism 8, and images each workpiece 2 and workpiece group 60 of transporter 1 while moving in the transport direction to acquire three-dimensional information such as positions and shapes of each workpiece 2 and workpiece group 60. Imaging device 5 can move within a movement range defined by upstream limit 8a and downstream limit 8b.
Object detector 3 is configured of, for example, a photoelectric sensor and is attached to transporter 1 to detect an object, that is, each workpiece 2 that passes through specific position A on transporter 1, thereby detecting that workpiece 2 to be transported has passed specific position A of transporter 1. Since object detector 3 continuously outputs a detection signal while detecting the object, as a result, it is also possible to detect a distance between workpiece 2 and workpiece 2 in the transport direction. It is desirable that object detector 3 is installed on an upstream side with respect to an upstream end of imaging device view field 10 of imaging device 5, which is located at an upstream end of the movement range, in the transport direction.
Object detector 3 detects timing when workpiece 2 to be transported has passed specific position A on transporter 1. As illustrating in
Movement amount detection device 4 is attached to transporter 1, and measures a workpiece movement amount of workpiece 2 by transporter 1 from specific position A after object detector 3 detects that workpiece 2 has passed specific position A to issue a measurement signal indicating the workpiece movement amount. An example of movement amount detection device 4 is an encoder attached to a motor that drives a belt in a case where transporter 1 is a belt conveyor.
Based on the measurement signal from movement amount detection device 4, movement mechanism 8 synchronizes imaging device 5 with the transport speed of workpiece 2 of transporter 1 and moves imaging device 5 in a transport direction parallel to the transport direction of transporter 1 at the same speed as the transport speed. Movement mechanism 8 is configured of, for example, a motor that is capable of driving forward/reverse rotation drive, a ball screw that is disposed in the transport direction and capable of forward/reverse rotation by the motor, and a support bracket that is screwed on the ball screw to support imaging device 5. Movement mechanism 8 advances and retreats the support bracket in the transport direction via the ball screw by the forward/reverse rotation of the motor.
Imaging processor 51 performs image processing based on the three-dimensional information acquired by imaging workpiece 2 while imaging device 5 moves in the transport direction, and acquires necessary information necessary for sorting specific workpiece 2a. That is, imaging processor 51 processes the image information of workpiece 2 imaged by imaging device 5 by image recognition, and derives the information of workpiece 2 necessary for sorting by robot 6, such as position coordinates, angles, and types.
Based on the necessary information acquired by imaging processor 51, robot 6 holds workpiece 2 to be transported, moves workpiece 2 from transporter 1 to a predetermined position outside transporter 1, and sorts workpiece 2.
Controller 52 receives the detection signal of object detector 3 and the measurement signal from movement amount detection device 4, and controls an operation of each of imaging device 5, movement mechanism 8, robot 6, and imaging processor 51 based on the input information and the transport speed of transporter 1.
A method of detecting the position of workpiece 2 on transporter 1 will be described.
Object detector 3 detects the timing when workpiece 2 has passed specific position A on transporter 1. Movement amount detection device 4 detects the movement amount of workpiece 2 by transporter 1 and outputs the measurement signal. By calculating the signal from object detector 3 and the measurement signal from movement amount detection device 4 by calculator 50, the position of workpiece 2 transported on transporter 1 in the transport direction on the downstream side of specific position A can be detected.
By grasping the position of each workpiece 2 by the above method, imaging device 5 can be controlled by controller 52 so that imaging device 5 attached to an upper portion of transporter 1 toward a transport surface of transporter 1 starts imaging at timing when workpiece 2 is placed in the view field. Here, “starts imaging at timing when workpiece 2 is placed in the view field” means when a shadow of one workpiece group 60 disappears and there is a space between workpiece group 60 and workpiece group 60, for example, when workpiece group 60 is projected in a transverse direction of the transporter while observing the upstream end of the imaging device view field.
After that, controller 52 sends the information of workpiece 2 necessary for sorting acquired from imaging processor 51 to robot 6 and also sends the measurement signal of movement amount detection device 4 to robot 6. Therefore, robot 6 picks only specific workpiece 2a of a specific type to be sorted from workpiece 2, and controller 52 controls robot 6 so as to move workpiece 2 to recovery box 7 outside transporter 1, thereby capable of sorting specific workpiece 2a.
Here, in a case where a three-dimensional imaging device capable of acquiring three-dimensional information is used as imaging device 5, it is possible to easily specify the type, the position, and specification of overlapping of workpiece 2, and to improve accuracy of sorting by robot 6.
However, in general, the three-dimensional imaging device takes time to capture an image, so when workpiece 2 being transported on transporter 1 is imaged, movement object blur occurs from a relationship between the transport speed of transporter 1 and an image capturing time of imaging device 5. Therefore, accurate information of workpiece 2 cannot be obtained and highly accurate picking cannot be performed.
Therefore, the movement object blur can be reduced by performing imaging while moving imaging device 5 in the transport direction at the same transport speed in synchronization with the movement of workpiece 2 of transporter 1. Therefore, movement mechanism 8 synchronizes imaging device 5 with the transport speed of transporter 1 to move imaging device 5 in the transport direction at the same transport speed and in parallel with the transport direction of transporter 1. Here, calculator 50 derives timing when workpiece 2 of an imaging object is transported into imaging device view field 10 of imaging device 5 from a signal from object detector 3, a measurement signal from movement amount detection device 4, and a current position of imaging device 5. Next, controller 52 issues an instruction to movement mechanism 8 so that movement mechanism 8 moves imaging device 5 in parallel while synchronizing with transporter 1, and reduces a relative speed between transporter 1, that is, workpiece 2 of the imaging object and imaging device 5.
Here, the position of imaging device 5 is detected by a position detector (for example, an encoder of a motor capable of driving forward/reverse rotation) included in movement mechanism 8 for moving imaging device 5, and the current position of imaging device 5 can be acquired.
Actually, controller 52 controls movement mechanism 8 so that movement mechanism 8 starts the movement of imaging device 5 at timing when an acceleration time is considered until imaging device 5 reaches a speed synchronized with transporter 1.
As described above, under the control of controller 52, imaging device 5 is moved in the transport direction in synchronization with transporter 1 to perform imaging by imaging device 5, so that even in three-dimensional imaging of workpiece 2 being transported using imaging device 5, it is possible to perform imaging with reduced movement object blur, and to perform sorting by highly accurate picking based on the imaging information.
However, when imaging device 5 moves in the transport direction, eventually, imaging device 5 ends up at downstream limit 8b in the transport direction, so it is necessary to perform an operation of returning of return imaging device 5 to an original position thereof. Here, the original position is, for example, upstream limit 8a in the transport direction of imaging device 5 in movement mechanism 8. The operation of returning imaging device 5 to the original position has to be performed during non-imaging of imaging device 5, that is, from the completion of imaging of certain workpiece group 60 to the start of imaging of next transported workpiece group 60. Therefore, calculator 50 derives the distance and position between workpiece groups 60 in the transport direction of workpiece group 60 based on the signal from object detector 3 and the measurement signal from movement amount detection device 4. Next, controller 52 issues an instruction to movement mechanism 8 of timing and a returning amount for returning imaging device 5 in a direction of the original position based on a derivation result of calculator 50.
In a case where each of workpiece groups 60 has the same shape and is transported on transporter 1 at equal intervals, the returning amounts by movement mechanism 8 may be the same and the timing may be a constant interval. In a case where each of workpiece groups 60 has an irregular shape or the timing of transport is random, it is necessary to control the adjustment of the returning amount and the timing.
Similarly, in a case where each of workpiece groups 60 has an irregular shape or the timing of transport is random, imaging device 5 may not return to the original position by one return operation depending on the distance between workpiece groups 60. That is, in order to image certain workpiece group 60, imaging device 5 images while being moved by movement mechanism 8, and after the imaging is completed and before starting the imaging of next workpiece group 60, it is necessary to move imaging device 5 to upstream limit 8a where movement mechanism 8 is the original position. However, in a case of a positional relationship in which before the movement of imaging device 5 to upstream limit 8a is completed, workpiece group 60 of the next imaging object passes through imaging device view field 10 of imaging device 5, it is necessary to start the next imaging before the movement to upstream limit 8a is completed. In that case, calculator 50 calculates a returning amount in time for the next imaging timing, and imaging device 5 returns to a position where the next imaging is possible based on the returning amount, and performs the next imaging.
Here, whether there is a case of a positional relationship in which workpiece group 60 of the next imaging object passes through imaging device view field 10 of imaging device 5 before the movement of imaging device 5 to upstream limit 8a is completed can be detected as follows. For example, the current position of workpiece group 60 can be detected by object detector 3 and movement amount detection device 4, and since the transport speed is known, a point, at which imaging device view field 10 of imaging device 5 attached to movement mechanism 8 trying to return to upstream limit 8a and workpiece group 60 to be transported intersect, can be acquired by calculation. When both sides reach that position, the next imaging is started.
With the above configuration, even in a case where imaging device 5 performs imaging while moving in the transport direction in synchronization with the transport operation by transporter 1, imaging device 5 does not end up at downstream limit 8b of movement mechanism 8 and can repeat the imaging. Upstream limit 8a and downstream limit 8b may be set at arbitrary positions instead of the physical end points of movement mechanism 8. However, upstream limit 8a needs to exist upstream of downstream limit 8b.
As described above, according to Exemplary Embodiment 1, imaging device 5 follows transporter 1 that transports workpiece 2 and can image workpiece 2 while moving imaging device 5 in parallel in the transport direction while synchronizing with the transport speed of transporter 1. Therefore, the three-dimensional information of workpiece 2 being transported, which could not be acquired in the past, can be acquired without movement object blur even by a three-dimensional imaging device that takes time to capture an image, and based on the acquired three-dimensional information, even workpiece 2 having a non-constant shape such as a disassembled product or a crushed product of goods can be picked with high accuracy to sort specific workpiece 2a.
The reciprocating operation of imaging device 5 by movement mechanism 8 in Exemplary Embodiment 1 is a repetition of the movement of imaging device 5 during imaging in the transport direction and the movement of imaging device 5 during non-imaging in the direction opposite to the transport direction. If the non-imaging time is shorter than the time for moving imaging device 5 from the position of imaging device 5 at the end of imaging to upstream limit 8a, imaging device 5 does not return to upstream limit 8a and imaging device 5 starts to move in the transport direction for imaging next workpiece group 60. By making the reciprocating operation of imaging device 5 by movement mechanism 8 efficient, the length of movement mechanism 8 can be designed to be short.
Based on the detection signal from object detector 3 and the measurement signal from movement amount detection device 4, calculator 50 specifies the position of workpiece group 20 configured of a plurality of workpieces 2 and not spaced in the transport direction. At the timing when the position is placed in the upstream side of imaging device view field 10, the imaging accompanied by the movement of imaging device 5 by movement mechanism 8 is started, so that the time loss is reduced and the reciprocating operation of imaging device 5 by movement mechanism 8 can be performed. That is, the position of workpiece group 20 in the imaging device view field is calculated by calculator 50 from the relationship between the position of workpiece group 20 in the transport direction obtained from object detector 3 and movement amount detection device 4 and the current position of imaging device 5, and this timing is calculated by calculator 50 as timing when only workpiece group 20, in which shadows of the plurality of workpieces 2 become one when workpiece group 20 is projected in a transverse direction of the transporter from a calculation result, is placed within the imaging device view field. Controller 52 controls movement mechanism 8 so as to start the movement of imaging device 5 at the calculated timing. By doing so, the time loss is small, and the reciprocating operation of imaging device 5 by movement mechanism 8 is possible.
Here, workpiece group 20 that is not spaced in the transport direction is workpiece group 20 in which the shadows of the plurality of workpieces 2 become one when workpiece 2 is projected in the transverse direction of the transporter. That is, in each of two different workpieces 20a and 20b constituting workpiece group 20 of
Xmax−a>Xmax−b>Xmin−a>Xmin−b (1)
Xmax−a>Xmax−b>Xmin−b>Xmin−a (2)
Workpiece 20a and workpiece 20b may be located opposite to each other in the transport direction.
If the above relational expressions (1) and (2) are satisfied for any two workpieces 20a and 20b, there is no upper limit to the number of workpiece groups 20 that are not spaced in the transport direction.
In a case where one workpiece 2 is being transported without forming workpiece group 20 that is not spaced in the transport direction, the imaging accompanied by the movement of imaging device 5 may be started by movement mechanism 8 at the timing when workpiece 2 is placed on the upstream side of imaging device view field 10.
As described above, the reciprocating operation of imaging device 5 by movement mechanism 8 can be made efficient, and the length of movement mechanism 8 can be designed to be short.
The reciprocating operation of movement mechanism 8 in Exemplary Embodiment 1 is a repetition of the movement during imaging in the transport direction and the movement during non-imaging in the direction opposite to the transport direction. If the non-imaging time is shorter than the time being moved from the position of imaging device 5 at the end of imaging to upstream limit 8a, imaging device 5 does not return to upstream limit 8a and starts to move from the middle of the movement in the opposite direction, that is, from the middle of returning, in the transport direction for imaging next workpiece group 60. Imaging processor 51 performs image processing on unprocessed workpiece group 60 existing in the captured image, and issues an instruction to robot 6 via controller 52.
In this way, by making the reciprocating operation of imaging device 5 by movement mechanism 8 efficient, the length of movement mechanism 8 can be designed to be short.
Based on the signal from object detector 3 and the measurement signal from movement amount detection device 4, the position of workpiece group 60 in the transport direction, the distance between workpiece groups 60 in the transport direction, and the waiting time until the imaging timing are calculated by calculator 50. At the same time, by calculating also the time required for the reciprocating operation of imaging device 5 by movement mechanism 8, it is possible to calculate time T1 to wait for the plurality of workpiece groups 60 that are not spaced in the transport direction respectively, that is, first workpiece group 30 and second workpiece group 31 in
In the example of
As described above, according to the picking device according to the exemplary embodiment of the present disclosure, the imaging device follows the transporter that transports the workpiece and can image the workpiece while moving the imaging device in parallel in the transport direction while synchronizing with the transport speed of the transporter. Therefore, the three-dimensional information of the workpiece being transported, which could not be acquired in the past, can be acquired without movement object blur even by the three-dimensional imaging device that takes time to capture the image, and based on the acquired three-dimensional information, even the workpiece having a non-constant shape such as a disassembled product or a crushed product of goods can be picked with high accuracy to sort the specific workpiece.
By appropriately combining any exemplary embodiment or modified example of the various exemplary embodiments or the modified examples, the effects of the respective exemplary embodiments or modified examples can be achieved. Further, it is possible to combine the exemplary embodiments or the examples, or the exemplary embodiments and the examples, and also to combine the features in the different exemplary embodiments or the examples.
Since the picking device according to the above aspect of the present disclosure can sort the workpiece that requires three-dimensional information by high-accurate picking, it is also possible to apply to a usage for sorting and recovering a workpiece of which a shape is not constant, such as a disassembled product or a crushed product of goods, or sorting fruits according to their shape or size.
Number | Date | Country | Kind |
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2020-207554 | Dec 2020 | JP | national |