Offline teaching device using simulation

The present application claims priority to Japanese Application Number 2014-130589, filed Jun. 25, 2014, the disclosure of which is hereby incorporated by reference herein in its entirety.

1. Technical Field

The present invention relates to an offline teaching device which teaches a robot position etc. using a simulation.

2. Description of the Related Art

Articulated robots are widely used on production lines etc. Before using these articulated robots, it is necessary to perform teaching operations on the articulated robots. Performing teaching operations by actually manipulating the articulated robot is inefficient so recently offline teaching operations are common.

Japanese Patent number 4621641 discloses a teaching method in which several pieces of tip information of a robot are set based on the CAD workpiece information, and based on the tip information thus set, the posture of the robot is calculated according to an inverse conversion operation. Further, Japanese Patent number 2868343 discloses an offline teaching method which performs teaching automatically and can improve processing quality when processing an uneven surface of a three dimensional workpiece.

Herein, a laser cutting operation using an articulated robot will be considered. In a laser cutting operation, directly after cutting a workpiece with a laser, the cut portion of the workpiece is cooled by cold water and accordingly the processing quality is improved. Further, by setting the time taken between cutting the workpiece and cooling the workpiece to a constant value, the processing quality can be maintained at a fixed level.

To improve the processing quality or maintain the processing quality at a fixed level in this way, it is necessary that the laser cutting tool and the cooling tool are maintained at a fixed distance and the cooling tool ejects cold water along the trajectory of the laser cutting tool. Therefore, when using an articulated robot to carry out a laser cutting operation, it is necessary to teach the robot position in which cold water is accurately ejected along the trajectory of the laser cutting tool. However, it was not possible to accurately teach such a robot position.

Moreover, if the laser cutting tool and the cooling tool are arranged to have a fixed distance therebetween, when laser machining is performed along a straight path, the time taken between cutting the workpiece and cooling the workpiece can be maintained at a fixed time. However when laser machining is performed along an arced path, the time taken from cutting the workpiece to cooling the workpiece is longer than for a straight path. Therefore, in this case, there was a problem that the processing quality decreased. Note that in machining operations other than the laser cutting operation the same problem would arise.

In view of such circumstances, it is the object of the present invention to provide an offline teaching device which can teach a robot position to accurately eject cold water along the trajectory of a laser cutting tool without the processing quality decreasing even when laser cutting is performed along an arced path.

In order to achieve the object, according to the first aspect of the present invention, an offline teaching device wherein a workpiece held by a robot is brought into contact with or is moved close to a first tool disposed at a predetermined position and a second tool separated by a predetermined distance from the first tool, to carry out work comprising: a holding position setting unit which sets the holding position of the workpiece held by the robot, a specification unit which specifies a work line on which the first tool carries out work according to CAD data of the workpiece, an installation position and posture setting unit which sets the installation position and posture of the first and second tools, a work posture setting unit which sets the work posture of the first tool with respect to the workpiece, a calculation unit which calculates a second position for the second tool on the work line, which is a position separated by the predetermined distance from a first position of the first tool on the work line, calculates a workpiece position where the first tool in the first position contacts or adjoins the workpiece, and calculates the workpiece position and posture such that the second tool in the second position contacts or adjoins the workpiece by changing the posture of the workpiece from the workpiece position with respect to the first tool, while maintaining the work posture of the first tool, and a generation unit which generates a robot teaching position based on the workpiece position and posture calculated by the calculation unit and the holding position of the workpiece set by the holding position setting unit and generates a program according to which the first tool and the second tool pass along the work line.

According to the second aspect of the present invention, there is provided an offline teaching device wherein a workpiece held by a robot is brought into contact with or is moved close to a first tool disposed at a predetermined position and a second tool which is three dimensionally moveable with respect to the first tool, to carry out work comprising: a holding position setting unit which sets the holding position of the workpiece held by the robot, a specification unit which specifies a work line on which the first tool carries out work according to CAD data of the workpiece, an installation position and posture setting unit which sets the installation position and posture of the first and second tools, a work posture setting unit which sets the work posture of the first tool with respect to the workpiece, a distance setting unit for setting the distance between the first tool and the second tool along the work line, a calculation unit which calculates a second position for the second tool on the workpiece positioned on the work line separated by the distance set by the distance setting unit from a first position on the workpiece on which the first tool will carry out work on the work line, calculates the workpiece position where the first tool which is in a work posture in the first position on the work line contacts or adjoins the workpiece, calculates the robot position based on the workpiece position and the holding position of the workpiece set by the holding position setting unit, and calculates the position of the second tool based on the workpiece position and the second position, a position teaching unit which teaches the robot position and the position of the second tool such that the first tool and the second tool pass along the work line and the distance therebetween along the work line is fixed.

According to the third aspect of the present invention, there is provided an offline teaching device comprising a robot to whose tip is affixed a first tool, and a second tool which is separated by a predetermined distance from the first tool, wherein the robot carries out work on a workpiece disposed in a predetermined position, while moving the first tool and the second tool, comprising: a specification unit which specifies a work line on which the first tool carries out work according to CAD data of the workpiece, an installation position and posture setting unit which sets the installation position and posture of the first and second tools, a work posture setting unit which sets the work posture of the first tool with respect to the workpiece, a calculation unit which calculates a second position for the second tool on the work line which is separated by the predetermined distance from a first position of the first tool on the work line, and calculates a robot position where the first tool in the first position contacts or adjoins the workpiece, and a generation unit which generates a robot position and posture as a robot teaching point when the second tool in the second position contacts or adjoins the workpiece by changing the posture of the robot from the robot position with respect to the first tool, while maintaining the work posture of the first tool, and generates a program according to which the first tool and the second tool pass along the work line.

According to the fourth aspect of the present invention, there is provided an offline teaching device comprising a robot to whose tip is affixed a first tool, and a second tool three dimensionally movable with respect to the first tool, wherein the robot carries out work on a workpiece disposed in a predetermined position while moving the first tool and the second tool, comprising: a specification unit which specifies a work line on which the first tool works according to CAD data of the workpiece, an installation position and posture setting unit which sets the installation position and posture of the first and second tools, a work posture setting unit which sets the work posture of the first tool with respect to the workpiece, a distance setting unit which sets the distance between the first tool and the second tool along the work line, a calculation unit which calculates a second position for the second tool on the workpiece, which is separated by the predetermined distance set by the distance setting unit, from a first position on the workpiece on which the first tool will carry out work on the work line, calculates a robot position where the first tool in the work posture contacts or adjoins the workpiece at a first position and calculates the position of the second tool based on the robot position and the second position, and a position teaching unit which teaches the robot position and the position of the second tool such that first tool and the second tool pass along the work line and the distance therebetween is fixed along the work line.

The above mentioned objects, features, and advantages and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the exemplary embodiments of the present invention illustrated in the accompanying drawings in which:

FIG. 1 is a schematic view of the system including the offline teaching device according to the first embodiment of the present invention.

FIG. 2 is a plan view of the workpiece shown in FIG. 1

FIG. 3 is a flowchart illustrating the operation of the offline teaching device according to the first embodiment of the present invention.

FIG. 4A is a first perspective view of the workpiece.

FIG. 4B is a second perspective view of the workpiece.

FIG. 5 is a schematic view of the system including the offline teaching device according to the second embodiment of the present invention.

FIG. 6 is a plan view of the workpiece illustrated in FIG. 5 .

FIG. 7 is a flowchart illustrating the operation of the offline teaching device according to the second embodiment of the present invention.

FIG. 8 is a schematic view of the system including the offline teaching device according to the third embodiment of the present invention.

FIG. 9 is a flowchart illustrating the operation of the offline teaching device according to the third embodiment of the present invention.

FIG. 10 is a schematic view of the system including the offline teaching device according to the fourth embodiment of the present invention.

FIG. 11 is a flowchart illustrating the operation of the offline teaching device according to the fourth embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described referring to the drawings. The same reference numbers for the same or corresponding constitutional elements are used over the drawings. The scale of the drawings showing the constitutional elements has appropriately been adjusted so as to facilitate the understanding of the present inventions.

FIG. 1 is a schematic view of the system including the offline teaching device according to the first embodiment of the present invention. As illustrated in FIG. 1 , the system 1 mainly comprises a robot R, for example a vertically articulated robot and an offline teaching device 10 which is connected to the robot R. The offline teaching device 10 has a role as a robot control device and controls the movement of robot R.

According to the first embodiment, a hand H affixed to the tip of the robot R holds a planar workpiece W. The first tool T 1 and the second tool T 2 are positioned so that the surface of the workpiece W can be processed along the work line L.

Further, the work line L, for example, includes four straight line paths and four arced paths which mutually connect the straight line paths. The same is true for the other embodiments. Note that it is necessary for the work line L to include at least one arced path.

In a typical embodiment, the first tool T 1 is a laser cutting tool wherein a laser is emitted from the tip thereof. In FIG. 1 , it is assumed that the first tool T 1 carries out cutting of the workpiece W along the work line L. The second tool T 2 is a cooling tool which ejects cold water from the tip thereof. Because of this the second tool T 2 tracks the first tool T 1 along the work line L on which the first tool T 1 carries out work. In other words, the first tool T 1 is positioned before the second tool T 2 in the direction of travel on the work line L.

However, the first tool T 1 may be a tool which cuts the workpiece by a method other than a laser. Further, the second tool T 2 may be a tool which cools the workpiece W by a method other than cold water. Alternatively, the first tool T 1 and the second tool T 2 may respectively be other tools.

As illustrated in FIG. 1 , an offline teaching device 10 is connected to the robot R. The offline teaching device 10 comprises a holding position setting unit 11 which sets the holding position of the workpiece W held by the robot R, a specification unit 12 which specifies a work line L on which the first tool T 1 will work based on CAD data of the workpiece W, an installation position and posture setting unit 13 which sets the installation position and posture of the first tool T 1 and the second tool T 2 and a work posture setting unit 14 which sets the work posture of the first tool T 1 with respect to the workpiece W. The setting and designating operations of the holding position setting unit 11 , specification unit 12 , installation position and posture setting unit 13 and the work posture setting unit 14 are performed before the operations which will be described with reference to the flowchart are performed.

Further, the offline teaching device 10 comprises a calculation unit 15 which processes a variety of calculations, and a generating unit 16 which generates a robot teaching position which will be discussed later as well as a program to allow the first tool T 1 and the second tool T 2 to pass along the work line.

Further, the offline teaching device 10 comprises a distance setting unit 17 which sets a distance between the first tool T 1 and the second tool T 2 along the work line, and a position teaching unit 18 which teaches the positions of the robot and the second tool T 2 so that the first tool T 1 and the second tool T 2 are moved along the work line and a fixed distance is maintained between the first tool T 1 and the second tool T 2 along the work line.

FIG. 2 is a plan view of the workpiece illustrated in FIG. 1 . As illustrated in FIG. 2 , the minimum distance between the first tool T 1 and the second tool T 2 of the first embodiment is fixed and does not change. Further, the first tool T 1 and the second tool T 2 pass along the same work line L.

As illustrated in FIG. 2 , when the first tool T 1 and the second tool T 2 are positioned on an arced path portion of the work line L, a straight line joining the first tool 1 and the second tool 2 is positioned on the inside of the work line L. Further, the work line L on the workpiece W is defined by a plurality of points P 1 n (n=1 to N, where N is a natural number and is determined corresponding to the length of the work line L) which are positioned at predetermined intervals.

FIG. 3 is a flowchart illustrating the operation of the offline teaching device according to the first embodiment of the present invention. The content illustrated in FIG. 3 is recorded in a storage unit (not illustrated) of the offline teaching unit 10 . The first embodiment of the present invention will be described with reference to FIG. 3 below. Note that the position of the first tool T 1 (or the second tool T 2 ) means the position of the tip of the first tool T 1 (or the second tool T 2 ).

Firstly, in step S 11 , the distance to the second tool T 2 from the first tool T 1 positioned on the first point P 11 (n=1) on the work line L is obtained. In the first embodiment this distance does not change and is fixed beforehand.

Then, in step S 12 , in a direction opposite the direction of movement of the first tool T 1 , a point P 21 on the work line L which is separated from the first point P 11 on the work line L by the distance determined in step S 11 is obtained.

Then, in step S 13 , a workpiece position W 1 where the first tool T 1 contacts or adjoins the first point P 1 on the work line L in the work posture set by the work posture setting unit 14 is obtained.

Herein, FIG. 4A is a first perspective view of the workpiece. As illustrated in FIG. 4A , the first tool T 1 is positioned on the point P 11 on the work line L, however, the second tool T 2 is apart from the point P 21 on the work line L. Note that in the first embodiment, the position of the workpiece illustrated in FIG. 4 is the workpiece position W 1 .

Referring again to FIG. 3 , in step S 14 , the position and posture of the workpiece W is changed from the workpiece position W 1 with respect to the point P 11 . As illustrated in FIG. 4A , when the work posture of the first tool T 1 is perpendicular to the workpiece W, the workpiece W is rotated about the point P 11 as shown by the arrow. Thereafter, as illustrated in FIG. 4B , the workpiece position and posture where the second tool T 2 contacts or adjoins the point P 21 on the work line L, is obtained. Further, in step 15 , a teaching point of the robot R is generated so that the workpiece position and posture obtained in step S 14 is realized.

Then, the next point P 12 (n+1→n=2) on the work line L is obtained and it is determined whether the point P 12 is the final point P 1 N on the work line L (steps S 16 and S 17 ). If the next point P 12 is not the final point P 1 N, the processes in steps P 12 to P 16 are repeated. If the next point P 12 is the final point P 1 N, it means that the program has been generated, and accordingly the operation ends.

In the first embodiment, teaching points are generated so that both the first tool T 1 and the second tool T 2 which are separated from one another at a fixed distance, pass along the work line which has been designated based on the CAD data. Because of this, a program according to which the first tool T 1 and the second tool T 2 pass along the common work line L while keeping a fixed distance from each other can be accurately generated. Additionally, in the case that the first tool T 1 is a laser cutting tool and the second tool T 2 is a cooling tool, cold water etc. can be accurately ejected along the trajectory of the laser cutting tool. Therefore, the machining quality of the workpiece can be improved.

FIG. 5 is a schematic view of a system comprising an offline teaching device according to the second embodiment of the present invention. For the purpose of brevity, in the second embodiment and other embodiments which will be discussed hereinafter no duplicate descriptions of the configurations of the components corresponding to those in the first embodiment will be given.

In the second embodiment, the hand H which is fixed to the tip of the robot R, holds a planar workpiece W. Then the first tool T 1 and the second tool T 2 machine the surface of the workpiece along the work line L.

As illustrated in FIG. 5 , the first tool T 1 is disposed at a predetermined position in the second embodiment. Further, the second tool T 2 is affixed to the tip of an XYZ table “A”. Because of this, the second tool T 2 can be moved in the XYZ directions with respect to the first tool T 1 so that the second tool 2 can be positioned in a desired position. Note that, instead of the XYZ table “A”, the second tool T 2 may be moved by another robot which is not illustrated.

FIG. 6 is a plan view of the workpiece illustrated in FIG. 5 . As illustrated in FIG. 6 , in the second embodiment, the distance between the first tool T 1 and the second tool T 2 along the work line L is fixed. This distance can be set by using the table XYZ “A”. Note that both the first tool T 1 and the second tool T 2 pass along the same work line L.

FIG. 7 is a flowchart illustrating the operation of the offline teaching device according to the second embodiment of the present invention. The content illustrated in FIG. 7 is recorded in the storage unit (not illustrated) of the offline teaching device 10 . The second embodiment of the present invention will be described below with reference to FIG. 7 .

Firstly, in step S 21 , the distance from the first tool T 1 positioned on the first point P 11 (n=1) on the work line L to the second tool T 2 is obtained. In the second embodiment, when the distance between the first tool T 1 and the second tool T 2 are set by the distance setting unit 17 , the XYZ table “A” positions the second tool T 2 at a position spaced by this distance from the first tool T 1 . Therefore, in step S 21 , the distance set by the distance setting unit 17 is obtained.

Then, in step S 22 , in a direction opposite the direction of movement of the first tool T 1 , the point P 21 on the work line L which is separated from the first point P 11 on the work line L by the distance determined in step S 21 is obtained.

Then, in step S 23 , the position teaching unit 18 teaches the point P 21 as the position for the second tool T 2 . Then, in step S 24 , the position teaching unit 18 generates a teaching point for the robot R so that the workpiece W moves to the point P 11 .

Then, the next point P 12 (n+1→n=2) on the line L is obtained. It is determined whether the point P 12 on the work line L is the final point PIN or not (steps S 25 and S 26 ). If the point P 12 is not the final point P 1 N, the operations in steps S 22 to S 25 are repeated. If the next point P 12 is the final point P 1 N, it means that the program has been generated and the operation ends.

In the second embodiment, in the state in which the second tool T 2 is moveable with respect to the first tool T 1 , the teaching position of the robot R and the teaching point of the second tool T 2 are generated so that the distance along the work line between the first tool T 1 and the second tool T 2 is a fixed distance. Because of this, an accurate program can be generated so that the first tool T 1 and the second tool T 2 move along the same work line with a fixed distance therebetween. Further, if the first tool T 1 is a laser cutting tool and the second tool T 2 is a cooling tool, the time taken to cool the workpiece W after the workpiece has been cut can be maintained at a fixed level. Therefore the processing quality of the workpiece can be maintained at a fixed level.

FIG. 8 is a schematic view of a system comprising an offline teaching device according to the third embodiment of the present invention. In the third embodiment, a first tool T 1 and a second tool T 2 are affixed to a base B attached to the tip of the robot R and the workpiece W is disposed at a predetermined position. In the third embodiment the first tool T 1 and the second tool T 2 process the surface of the workpiece W along the work line L. As in the first embodiment with reference to FIG. 2 , the minimum distance between the first tool T 1 and the second tool T 2 is fixed and does not change.

FIG. 9 is a flowchart which illustrates the operation of the offline teaching device according to the third embodiment of the present invention. The content illustrated in FIG. 9 is recorded in the storage unit (not illustrated) of the offline teaching unit 10 . The third embodiment is described below with reference to FIG. 9 .

Firstly, in step S 31 , the distance to tool T 2 from the tool T 1 which is positioned at the first point P 11 (n=1) on the work line L is obtained. In the third embodiment this distance is constant and is predetermined.

Then in step S 32 , in a direction opposite the direction of movement of the first tool T 1 , the point P 21 on the work line L, which is spaced from the first point P 11 on the work line L by a distance determined in step S 31 , is obtained.

Then, in step S 33 , a robot position R 1 is obtained where the first tool T 1 contacts or adjoins the first point P 1 on the work line L in the work posture set by the work posture setting unit 14 . In the third embodiment, the position shown in FIG. 4A corresponds to the robot position R 1 .

In step S 34 , the position and the posture of the robot R is changed from the robot position R 1 with respect to the point P 11 . As illustrated in FIG. 4A , when the work posture of the first tool T 1 is perpendicular to the workpiece W, the robot R is rotated about the point P 11 as indicated by the arrow. Further, as indicated in FIG. 4B , a robot position and posture where the second tool T 2 contacts or adjoins the point P 21 on the work line L, is obtained. Further, in step S 35 , a teaching point for robot R is generated so that the robot position and posture determined in step S 34 are obtained.

Then, the next point P 12 (n+1→n=2) on the work line L is obtained, and it is determined whether the point P 12 is the last point PIN on the work line L or not (steps S 36 and S 37 ). If the next point P 12 is not the final point P 1 N, the operations in steps S 32 to S 36 are repeated. If the next point P 12 is the final point P 1 N, the control ends as a program has been generated.

In the third embodiment, teaching points are generated so that both the first tool T 1 and the second tool T 2 which are disposed at a fixed distance from each other pass along the work line specified based on the CAD data. Therefore, an accurate program can be generated where the first tool T 1 and the second tool T 2 pass along the same work line L at a fixed distance from each other. Thus, if the first tool T 1 is a laser cutting tool and the second tool T 2 is a cooling tool, cold water can be accurately ejected along the trajectory of the laser cutting tool. Therefore, the processing quality of the workpiece can be improved.

FIG. 10 is a schematic view of the system comprising the offline teaching device according to the fourth embodiment of the present invention. In the fourth embodiment, the first tool T 1 is affixed to an end of a base B which is affixed to the tip of the robot R. The XYZ table C is affixed to the other end of the base B. The tool T 2 is affixed to the tip of the XYZ table C. Therefore, the second tool 2 is movable in the XYZ directions with respect to the first tool T 1 so that the second tool T 2 can be positioned in a desired position. Note that instead of the XYZ table C, the second tool T 2 may be moved by another robot which is not illustrated.

Further, the workpiece W is held at a predetermined position. In the fourth embodiment, the first tool T 1 and the second tool T 2 perform processing of the workpiece W on the surface thereof along the work line L.

FIG. 11 is a flowchart which illustrates the operation of the offline teaching device according to the fourth embodiment of the present invention. The content illustrated in FIG. 11 is recorded in the storage unit (not illustrated) of the offline teaching device 10 . The fourth embodiment of the present invention will be described below with reference to FIG. 11 .

Firstly, in step S 41 , the distance to the second tool T 2 from the first tool T 1 positioned on the first point P 11 (n=1) on the work line L is obtained. In the fourth embodiment, when the distance setting unit 17 sets the distance between the first tool T 1 and the second tool T 2 , the XYZ table C moves the second tool T 2 to a position spaced away from tool T 1 by this distance. Therefore, in step S 41 , the distance set by the distance setting unit 17 may be obtained.

Then, in step S 42 , the point P 21 which is spaced from the first point P 11 on the work line L by the distance established in the step S 41 in a direction opposite the direction of movement of the first tool T 1 is determined.

Then, in step 43 , the position teaching unit 18 generates a teaching point of robot R such that the robot R moves to the point P 11 . Then, in step 44 , the position teaching unit 18 teaches the position P 21 as the position of the second tool T 2 .

Then, the next point P 12 (n+1→n=2) on the work line L is obtained, and it is determined whether the point P 12 is the final point PIN on the work line L or not (step S 45 and step S 46 ). If the next point P 12 is not the final point P 1 N, the operations in steps 42 to 45 are repeated. If the point P 12 is the final point P 1 N, processing is stopped as the program has been generated.

In the fourth embodiment, the teaching position of the robot R and the teaching position of the second tool T 2 are generated such that the distance between the first tool T 1 and the second tool T 2 along the work line is kept constant in the state that the second tool T 2 is moveable with respect to the first tool T 1 . Because of this, an accurate program according to which the tool T 1 and the tool T 2 pass along the same work line while maintaining a fixed distance therebetween, can be generated. Furthermore, if the first tool T 1 is a laser cutting tool and the second tool T 2 is a cooling tool, the time taken for the workpiece W to be cooled after being cut is kept constant. Therefore the processing quality of the workpiece W can be kept constant.

Advantageous Effects of the Invention

According to the first and third embodiments, teaching points are generated such that both the first tool T 1 and the second tool T 2 which are spaced from one another at a fixed distance pass along the work line designated from the CAD data. Because of this, an accurate program can be generated for the tool T 1 and the tool T 2 to pass along the same work line while maintaining a fixed distance therebetween. Thus, if the first tool T 1 is a laser cutting tool and the second tool T 2 is a cooling tool, cold water can be accurately ejected along the trajectory of the laser cutting tool. Therefore the processing quality of the workpiece can be improved.

In the second and fourth embodiments, the second tool is moveable with respect to the first tool, thus the teaching position of the robot and the teaching position of the second tool can be generated such that the distance between the first tool and the second tool along the work line is constant. Because of this, an accurate program can be generated for the tool T 1 and the tool T 2 to pass along the same work line while maintaining a fixed distance therebetween. Thus, if the first tool is a laser cutting tool and the second tool is a cooling tool, the time taken for the workpiece to be cooled after being cut is kept constant. Therefore the processing quality of the workpiece can be kept constant.

Typical embodiments of the present invention have been described; however, it should be obvious to a person skilled in the art that without departing from the scope of the present invention, the aforementioned changes and various other changes, omissions and additions can be carried out.