A control apparatus that controls a robot system including a part feeder having a container that accommodates a part and a plurality of vibration actuators for vibrating the container, and a robot having an end effector for picking up a part from the container, the apparatus comprising: a processor that is configured to execute computer-executable instructions so as to control the part feeder and the robot, wherein the processor is configured to select one or more control commands from a plurality of control commands respectively including control parameters of the plurality of vibration actuators and transmits the selected control command to the part feeder for causing the part feeder to perform an operation according to the selected control command.

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Patent
   RE50190
Priority
Jun 06 2017
Filed
Dec 29 2022
Issued
Oct 29 2024
Expiry
Jun 05 2038
Inventors
Kinoshita,…
Assg.orig
Seiko Epso…
Assg.curr
Seiko Epso…
Entity
Large
Referenced by
0
References
18
Maint.:
currently ok
E. Fifth Embodiment
F. Initial Setting o…
16. A robot system comprising:
a part feeder having a container that accommodates a plurality of parts and a plurality of vibration actuators for vibrating the container;
a robot having an end effector for picking up one of the parts from the container;
a camera configured to capture an image of the parts;
a memory configured to store computer-executable instructions, a plurality of control commands including first control command and second control command, and image data of the parts including first image data, second image data, and third image data; and
a processor that is configured to execute the computer-executable instructions so as to:
cause the camera to capture the image of the parts in the container so as to create captured image corresponding to captured image data;
compare the captured image data with the image data stored in the memory;
perform a first activation in which at least one of the vibration actuators transmits vibration to the container so as to move the parts from a distal end to a proximal end of the container along a first direction when the captured image data correspond to the first image data, the distal end of the container being directly adjacent to a supply source of the parts, the proximal end of the container being directly adjacent to a part tray;
perform a second activation in which the vibration actuators transmit vibration to the container so as to flip the parts in the container when the captured image data correspond to the second image data; and
cause the end effector to pick up one of the parts located near the proximal end of the container and move the picked part to the part tray when the captured image data correspond to the third image data,
wherein the processor selects the first control command in the first activation, and the processor selects the second control command in the second activation, and
a vibration time of the vibration corresponding to the first control command is longer than a vibration time of the vibration corresponding to the second control command. A robot system comprising: a part feeder having a container that accommodates a part and a plurality of vibration actuators for vibrating the container; a robot having an end effector for picking up a part from the container; and the control apparatus having a processor that is configured to execute computer-executable instructions so as to control the part feeder and the robot, wherein the processor is configured to select one or more control commands from a plurality of control commands respectively including control parameters of the plurality of vibration actuators and transmits the selected control command to the part feeder for causing the part feeder to perform an operation according to the selected control command, the number of the vibration actuators is four, and the vibration actuators are mounted at four corners of a part accommodating region, the plurality of control commands include a separation command for causing the part feeder to execute a separation operation to separate a plurality of parts gathered in the container, the plurality of control commands include a posture change command for causing the part feeder to execute a posture change operation to change a posture of a part in the container.
1. A control apparatus that controls a robot system including a part feeder having a container that accommodates a plurality of parts and a plurality of vibration actuators for vibrating the container, and a robot having an end effector for picking up one of the parts from the container, the control apparatus comprising:
a memory configured to store computer-executable instructions, a plurality of control commands including first control command and second control command, and image data of the parts including first image data, second image data, and third image data; and
a processor that is configured to execute the computer-executable instructions so as to:
cause a camera to capture an image of the parts in the container so as to create captured image corresponding to captured image data;
compare the captured image data with the image data stored in the memory;
perform a first activation in which at least one of the vibration actuators transmits vibration to the container so as to move the parts from a distal end to a proximal end of the container along a first direction when the captured image data correspond to the first image data, the distal end of the container being directly adjacent to a supply source of the parts, the proximal end of the container being directly adjacent to a part tray;
perform a second activation in which the vibration actuators transmit vibration to the container so as to flip the parts in the container when the captured image data correspond to the second image data; and
cause the end effector to pick up one of the parts located near the proximal end of the container and move the picked part to the part tray when the captured image data correspond to the third image data,
wherein the processor selects the first control command in the first activation, and the processor selects the second control command in the second activation, and
a vibration time of the vibration corresponding to the first control command is longer than a vibration time of the vibration corresponding to the second control command.
2. The control apparatus according to claim 1,
wherein the plurality of control commands include third control command, and
the processor is configured to perform a third activation in which the vibration actuators transmit vibration to the container so as to separate the parts gathered in the container when the processor selects the third control command. A control apparatus that controls a robot system including a part feeder having a container that accommodates a part and a plurality of vibration actuators for vibrating the container, and a robot having an end effector for picking up a part from the container, the apparatus comprising: a processor that is configured to execute computer-executable instructions so as to control the part feeder and the robot, wherein the processor is configured to select one or more control commands from a plurality of control commands respectively including control parameters of the plurality of vibration actuators and transmits the selected control command to the part feeder for causing the part feeder to perform an operation according to the selected control command, the number of the vibration actuators is four, and the vibration actuators are mounted at four corners of a part accommodating region, the plurality of control commands include a separation command for causing the part feeder to execute a separation operation to separate a plurality of parts gathered in the container, and the plurality of control commands include a posture change command for causing the part feeder to execute a posture change operation to change a posture of a part in the container.
3. The control apparatus according to claim 2,
wherein the container includes a the part accommodating region and an outer peripheral wall provided at an outer periphery of the part accommodating region, and an interference region where a gripping mechanism of the end effector interferes with the outer peripheral wall exists in the outer periphery of the part accommodating region,
wherein the plurality of control commands include fifth control a part moving command,
the processor is configured to perform a fifth an activation in which the vibration actuators transmit vibration to the container so as to move the parts existing in the interference region toward an inside of the part accommodating region when the processor selects the fifth control part moving command, and
the processor performs the fifth activation after the processor performs the third activation.
0. 4. The control apparatus according to claim 2,
wherein the plurality of control commands include fourth control command, and
the processor is configured to perform a fourth activation in which the vibration actuators transmit vibration to the container so as to change a posture of one of the parts in the container when the processor selects the fourth control command.
5. The control apparatus according to claim 4, claim 2,
wherein a vibration time of the vibration corresponding to the third control separation command is longer than a vibration time of the vibration corresponding to the fourth control posture change command.
6. The control apparatus according to claim 1, claim 2,
wherein the processor is configured to:
perform image recognition for recognizing at least one of the parts in the container based on the a captured image; and
select one or more control commands from the plurality of control commands using a result of the image recognition and transmit the selected control command to the part feeder.
7. The control apparatus according to claim 6,
wherein the processor is configured to virtually divide an accommodating region of the container into a plurality of partitions including a replenishment partition that receives the parts from the a supply source and a picking partition in which the end effector picks up one of the parts,
wherein, when one of the parts existing in the picking partition is recognized by the image recognition, the processor controls the robot so as to pick up the recognized part by the end effector, and
wherein, when no existence of one of the parts in the picking partition is recognized by the image recognition, the processor selects the a first control command to the part feeder to move the parts from a partition other than the picking partition to the picking partition.
8. The control apparatus according to claim 7,
wherein, when one of the parts that is not capable of picking up by the end effector in the picking partition is recognized by the image recognition, the processor selects the a second control command to flip the one of the parts in the container.
9. The control apparatus according to claim 7,
wherein the plurality of partitions further includes an intermediate partition provided between the replenishment partition and the picking partition along the a first direction, and
wherein, when the processor selects the first control command, the parts existing in the replenishment partition move to the intermediate partition and the parts existing in the intermediate partition move to the picking partition.
10. The control apparatus according to claim 7,
wherein the end effector has a first pick-up mechanism and a second pick-up mechanism, and
wherein the processor is configured to perform:
a process of recognizing one of the parts existing in the picking partition as a first pickable part picked by the first pick-up mechanism;
a process of picking up the first pickable part with the first pick-up mechanism; and
a process of recognizing another of the parts existing in the picking partition as a second pickable part picked by the second pick-up mechanism when the first pickable part is held by the first pick-up mechanism.
11. The control apparatus according to claim 10,
wherein the processor is configured to perform a process of recognizing some parts of the parts existing in the picking partition as the second pickable parts picked by the second pick-up mechanism, and
the processor is configured to select one of the second pickable parts picked by the second pick-up mechanism based on a locational relationship between the second pick-up mechanism and the second pickable parts when the first pickable part is held by the first pick-up mechanism.
12. The control apparatus according to claim 1, claim 6,
wherein the processor is configured to perform:
a setting process of setting additional regions at a plurality of places of an outer edge of each of the parts in the captured image, the additional regions are gripped by a gripping mechanism of the end effector; and
a recognition process of recognizing one of the parts in which the additional regions do not overlap with another part as a grippable part in the captured image, and
wherein the processor is configured to control the robot so as to grip and pick up the grippable part with the gripping mechanism of the end effector.
13. The control apparatus according to claim 12,
wherein the processor is configured to perform:
an image update process of updating the captured image by deleting the grippable part from the captured image after the recognition process so as to create an updated image; and
a repetition process of repeating the recognition process and the image update process using the updated image,
wherein the processor is configured to create an order in which the part is recognized as the grippable part when the recognition process and the image update process are repeated and to store the order in the memory, and
wherein the processor is configured to control the robot so as to grip and pick up the part with the gripping mechanism of the end effector according to the order.
14. The control apparatus according to claim 1, claim 2,
wherein, when the vibration actuators transmit vibration to the container, the vibration is created based on control parameters including a frequency of a vibration signal to be supplied to each of the vibration actuators, amplitude of the vibration signal, and a vibration time.
15. The control apparatus according to claim 14,
wherein the memory stores the control parameters of the plurality of vibration actuators, and
wherein the control parameters stored in the memory include
(a) balance of vibration intensity between the plurality of vibration actuators,
(b) a frequency of the vibration signal that is capable of activating a motion of at least one of the parts existing in the container, and
(c) amplitude of the vibration signal that is capable of preventing one of the parts existing in the container from jumping out of the container.
0. 17. The robot system according to claim 16,
wherein the plurality of control commands include third control command, and
the processor is configured to perform a third activation in which the vibration actuators transmit vibration to the container so as to separate the parts gathered in the container when the processor selects the third control command.
0. 18. The robot system according to claim 17,
wherein the Plurality of control commands include fourth control command, and
the processor is configured to perform a fourth activation in which the vibration actuators transmit vibration to the container so as to change a posture of one of the parts in the container when the processor selects the fourth control command.
19. The robot system according to claim 18 claim 16,
wherein a vibration time of the vibration corresponding to the third control separation command is longer than a vibration time of the vibration corresponding to the fourth control posture change command.
20. The robot system according to claim 16,
wherein the processor is configured to:
perform image recognition for recognizing at least one of the parts in the container based on the a captured image; and
select one or more control commands from the plurality of control commands using a result of the image recognition and transmit the selected control command to the part feeder.

Here, Sp is a sum of areas of parts PP in the end portion region EA, and Se is an area of the end portion region EA. For example, in a case where a part PP is recognized as a black image, it is possible to calculate the parts area Sp as the number of black pixels in the end portion region EA.

A width Wea of the end portion region EA is set to be smaller than a width of the picking partition RA. For example, it is preferable to set the width Wea of the end portion region EA to a value in a range of one to two times the width of the part PP. In the example of FIG. 16, the end portion region EA is set on the left side of the part accommodating region 412, but a position of the end portion region EA is set according to a movement direction of the part PP in the feed operation. That is, it is preferable that the end portion region EA is set near a side which is the terminal end in a direction of the feed operation among four sides of the part accommodating region 412.

In a case where the uneven distribution ratio Ru of the parts is equal to or greater than a predetermined threshold, since the parts PP are unevenly distributed as illustrated in FIG. 16, it is preferable to perform the back feed operation in step S155. The time of the back feed operation may be determined according to the uneven distribution ratio Ru. Specifically, it is preferable to lengthen the back feed time as the uneven distribution ratio Ru increases.

Various pieces of control may be executed using the image recognition result other than the uneven distribution ratio Ru of the parts.

FIG. 17 illustrates an example of various platform states obtained by the image recognition. The “platform” means the part accommodating region 412. Here, the following seven states are exemplified.

State 1: Pickable State

A state where parts are dispersed in a pickable state in the platform.

State 2: Empty State

A state where there is no part in the platform.

State 3: Unevenly Distributed Pick Position State

A state where parts are unevenly distributed at the end portion of the platform. The state 3 corresponds to the state described in FIG. 16.

State 4: Excessively Large Number of Remaining Parts State

A state where the remaining number of parts is 20% or more than an appropriate number.

State 5: Excessively Small Number of Remaining Parts State

A state where the remaining number of parts is 20% or less than the appropriate number.

State 6: Excessively Large Number of Remaining Backward-Facing Parts State

A state where the remaining number of backward-facing parts is 10% or more than the appropriate number.

State 7: No Pickable Parts State

A state where there are no parts required to be picked up although the parts exist in the platform and only another type of part exists.

The states can be used for executing various pieces of control and adjusting the control contents. For example, in a case where state 2 or state 7 is recognized at a predetermined point in time, the process may jump to step S200 of FIG. 15 to replenish the parts. In a case where state 4 or state 5 is recognized, the number of replenishments in step S170 may be changed according to the remaining number of parts. In this manner, when the control contents are adjusted according to various image recognition results, it is possible to further improve the work efficiency. The adjustment of the control contents according to such image recognition results can be employed in other embodiments. The point that the back feed operation of step S155 is performed after the feed operation of step S150 can also be employed in other embodiments.

E. Fifth Embodiment

FIG. 18 is a conceptual diagram of a robot system in a fifth embodiment. The robot system is the same as the robot system of the first embodiment (FIG. 1) and the third embodiment (FIG. 10) except for the end effector 160c. The end effector 160c is a gripper having double hands that can grip and pick up two parts using two gripping mechanisms 164.

FIG. 19 is a plan view of the end effector 160c. The end effector 160c has two gripping mechanisms 164a and 164b, and two vertical movement mechanisms 166a and 166b. The gripping mechanisms 164a and 164b are grippers that grip the parts PP at three points in this example. The vertical movement mechanisms 166a and 166b can change heights of the two gripping mechanisms 164a and 164b by respectively moving the gripping mechanisms 164a and 164b in the vertical direction (Z direction). A relative height of the two gripping mechanisms 164a and 164b may be changed using one vertical movement mechanism, by omitting one of the two vertical movement mechanisms 166a and 166b.

FIGS. 20A to 20D are explanatory diagrams illustrating a recognition process of parts PP that can be gripped by the two gripping mechanisms 164a and 164b. The image recognition unit 214 first recognizes a part PP1 that can be gripped by a first gripping mechanism 164a (FIG. 20A). The part PP1 is referred to as “first grippable part PP1”. Next, the image recognition unit 214 recognizes a position of a second gripping mechanism 164b in a state of gripping the first grippable part PP1 with the first gripping mechanism 164a (FIG. 20B). At this time, the image recognition unit 214 calculates a coordinate and a gripping angle (angle around Z-axis) of the second gripping mechanism 164b using a positional relationship in the horizontal direction of the two gripping mechanisms 164a and 164b. Then, the image recognition unit 214 recognizes a part PP2 that can be gripped by the second gripping mechanism 164b (FIG. 20C). The part PP2 is referred to as “second grippable part PP2”. In this manner, when the process of recognizing the second grippable part PP2 that can be gripped by the second gripping mechanism 164b is executed in the state of gripping the first grippable part PP1 with the first gripping mechanism 164a, it is possible to improve the efficiency of the work of picking up the parts PP using the two gripping mechanisms 164a and 164b.

As the second grippable part PP2, it is preferable to select a part PP that is most easily gripped by the second gripping mechanism 164b in the state of gripping the first grippable part PP1 with the first gripping mechanism 164a. The selection can be performed, for example, according to a pick-up cost. The “pick-up cost” is calculated according to a predetermined calculation method with respect to one or more parts PP that can be gripped by the second gripping mechanism 164b in the state of gripping the first grippable part PP1 with the first gripping mechanism 164a.

The following various types of method can be considered as the calculation method of the pick-up cost.

(1) Pick-Up Cost Calculation Method 1

A trajectory of the robot 100 required for gripping one or more parts PP near the second gripping mechanism 164b by the second gripping mechanism 164b is calculated from the state (FIG. 20A) of gripping the first grippable part PP1 with the first gripping mechanism 164a, and a time for moving the trajectory is taken as the pick-up cost.

(2) Pick-Up Cost Calculation Method 2

A distance between the second gripping mechanism 164b and each part PP is calculated for one or more parts PP near the second gripping mechanism 164b from the state (FIG. 20A) of gripping the first grippable part PP1 with the first gripping mechanism 164a, and the distance is taken as the pick-up cost.

(3) Pick-Up Cost Calculation Method 3

A rotation angle (rotation angle of torsional joint J4) of the end effector 160c required for gripping one or more parts PP near the second gripping mechanism 164b by the second gripping mechanism 164b is calculated from the state (FIG. 20A) of gripping the first grippable part PP1 with the first gripping mechanism 164a, and the rotation angle is taken as the pick-up cost.

The second grippable part PP2 illustrated in FIG. 20C is a part in which the pick-up cost calculated by the calculation method 2 is minimized. The second grippable part PP2 illustrated in FIG. 20D is a part in which the pick-up cost calculated by the calculation method 3 is minimized. In a case where a position for gripping the part PP is determined in advance according to a shape of the part PP as the part PP in the embodiment, the calculation method 1 (trajectory reference) or the calculation method 3 (rotation angle reference) is suitable. On the other hand, in a case where a position for picking up the part PP by the end effector 160 does not depend on the shape of the part PP (for example, case of using adsorption pick-up mechanism) as the part PP in the first embodiment, the calculation method 1 (trajectory reference) or the calculation method 2 (distance reference) is suitable.

As described above, when the pick-up cost is respectively calculated according to the predetermined calculation method with respect to one or more parts PP that can be gripped by the second gripping mechanism 164b in the state of gripping the first grippable part PP1 with the first gripping mechanism 164a, and the second grippable part PP2 is selected according to the pick-up costs, it is possible to improve the efficiency of gripping the part with the second gripping mechanism 164b.

The selection of two grippable parts as described above can also be employed in a robot including an end effector having two pick-up mechanisms (for example, adsorption pick-up mechanisms) other than the gripping mechanism 164. In this case, the image recognition unit 214 executes a process of recognizing a second pickable part PP2 that can be picked up by a second pick-up mechanism in a state of holding a first pickable part PP1 with a first pick-up mechanism. In this manner, it is possible to improve the efficiency of picking up the part with the second pick-up mechanism.

F. Initial Setting of Control Parameters of Part Feeder

FIG. 21 is a flowchart of an initial setting of control parameters of the part feeder 400, and FIGS. 22A to 22E are explanatory diagrams illustrating process contents of steps S420 to S450 of FIG. 21. The process is executed before performing the pick-up work of the part PP by the robot 100 described above. The process is executed by acquiring an image of parts PP in the part accommodating region 430 by the camera 430 and analyzing the image by the control parameter setting unit 215.

In step S410, a balance adjustment of vibration intensity of the plurality of vibration actuators 424 is performed. The adjustment is performed for compensating a tilt of the part accommodating region 412 and differences in characteristics of each vibration actuator 424. Specifically, for example, the plurality of parts PP are accommodated in the part accommodating region 412, the plurality of vibration actuators 424 are vibrated in the same phase, and a coordinate (XY coordinate) of each part PP is acquired. Then, amplitude of a vibration signal supplied to each vibration actuator 424 is adjusted such that coordinates of the plurality of parts PP are not unevenly distributed and an average value of the coordinates positions at the center of the part accommodating region 412. The balance of the vibration intensity adjusted as described above is used also after step S420.

In step S420, a frequency that can activate the motion of the parts PP is measured. In the measurement process, for example, one part PP is accommodated in the part accommodating region 412, the vibration actuators 424 with the predetermined number are vibrated, and a movement amount of the part PP is acquired. Then, a frequency of the vibration signal that maximizes the movement amount of the part PP is adjusted.

FIG. 22A illustrates an example of a relationship between the frequency and the part activity (movement amount of parts PP) in step S420. In this example, a frequency Fc at the peak of the graph is measured as the frequency that can activate the motion of the parts. The frequency Fc is, for example, a value equal to the resonance frequency of the part accommodating region 412. The appropriate frequency determined as described above is used also after step S430.

As the number of vibration actuators 424 used in step S420, a predetermined number of one or more can be used. The frequency that can activate the motion of the parts may be measured for each combination of the used number of the vibration actuator 424 and a used place thereof. For example, in a case where the part feeder 400 includes four vibration actuators 424a to 424d and one, two, or four of the four vibration actuators are used, the number of combinations of the used number of the vibration actuator 424 and the used place thereof is eleven in maximum. In a case where two or four vibration actuators 424 are used, the frequency that can activate the motion of the parts may be measured for each of phase difference values (for example, 0 degrees and 180 degrees) of the vibration actuators. In this manner, the point that it is preferable to set the appropriate control parameter for each combination of the used number of the vibration actuator 424 and the used place thereof is the same as other control parameters described below.

In step S430, amplitude that can prevent jump-out of the parts PP is measured. The amplitude is amplitude as large as possible within a limit in which the parts PP do not jump out of the part accommodating region 412. In the measurement process, for example, the plurality of parts PP are accommodated in the part accommodating region 412, the plurality of vibration actuators 424 are vibrated, and it is determined from an image of the camera 430 whether the parts PP jump out of the part accommodating unit 410. The determination is performed while gradually increasing the amplitude of the vibration signal to obtain maximum amplitude at which the jump-out of the parts PP is not detected.

FIG. 22B illustrates an example of a relationship between the amplitude in step S430 and the part activity. In this example, maximum amplitude Amax at which the jump-out of the parts PP is not detected is measured as amplitude that can prevent jump-out of the parts PP. The appropriate amplitude determined as described above is used also after step S440.

In step S440, the appropriate number of parts PP in the part feeder 400 is determined. In this process, for example, a lot of parts PP are accommodated in the part accommodating region 412, the separation operation (FIG. 4B) is performed, and then an image acquired by the camera 430 is analyzed to obtain the number of the parts PP that can be picked up. It is preferable to determine whether the picking up is possible by ignoring the front and back of the part PP. In this case, for example, a part PP which is not overlapped with another part PP at all is determined as the part that can be picked up. This process is executed respectively under conditions that the number of parts PP accommodated in the part accommodating region 412 is subsequently changed, and the number of parts when the number of parts that can be picked up is the maximum is determined as the appropriate number of parts in the part feeder 400.

FIG. 22C illustrates an example of a relationship between the number of parts in the part feeder 400 in step S440 and the number of parts detected as pickable. In this example, the number of parts in the part feeder 400 when the number of detected parts peaks is determined as the appropriate number of parts in the part feeder 400. The appropriate number of parts determined as described above is used also after step S450. In the case where the part PP is held using the gripping mechanism 164 as in the third to fifth embodiments, a window PW may be provided around the part PP in consideration of portions gripped by the gripping mechanism 164 as illustrated in FIG. 22C, and a part PP in which the window PW thereof does not overlap with the outline of another part PP may be recognized as “part PP that can be picked up”. Alternatively, the additional regions AD (FIG. 13A) described in the third embodiment may be used instead of the window PW.

It is possible to determine the appropriate number of parts using simulation instead of actually performing an experiment to supply the parts to the part feeder 400.

FIG. 22D is an explanatory diagram illustrating a process of determining the number of parts by simulation. At this time, one part is first imaged using the camera 430, and a part image Mp is cut out. Then, an image in which the cut out part image Mp is disposed randomly in a region R412 having the same shape as the part accommodating region 412 is created by simulation. Then, the number of parts that can be picked up is obtained by analyzing the simulation image. When this process is executed a plurality of times while changing the number of part images Mp in the region R412, it is possible to obtain the same characteristics as those in FIG. 22C by simulation. Then, it is possible to determine the number of parts in the part feeder 400 when the number of detected parts peaks as the appropriate number of parts in the part feeder 400. In this manner, when the appropriate number of parts is determined using simulation, it is possible to omit the labor of performing the experiment.

In step S450, control parameters of the separation command are adjusted. In the adjustment process, for example, the plurality of parts PP are accommodated in the part accommodating region 412, the separation operation (FIG. 4B) by the separation command is performed, and then an image acquired by the camera 430 is analyzed to obtain the number of the parts PP that can be picked up. It is preferable to determine whether the picking up is possible by ignoring the front and back of the part PP. It is preferable that the number of parts PP accommodated in the part accommodating region 412 is, for example, the appropriate number of parts determined in step S440. This process is executed respectively under conditions that the continuing time of the separation operation is subsequently changed, and a value in which the number of parts that can be picked up is sufficiently large and the continuing time of the separation operation is not excessively long is determined as the continuing time of the separation operation.

FIG. 22E illustrates an example of a relationship between the continuing time of the separation operation in step S450 and the number of parts detected as pickable. In this example, results obtained in three cases where the number of parts in the part feeder 400 is 130, 65, and 33 are illustrated for reference. As can be understood from the examples, the detected number of parts PP that can be picked up increases as the continuing time of the separation operation increases, but saturates after reaching certain continuing times. Therefore, continuing times (times indicated by open circles in FIG. 22E) in which the number of parts that can be picked up is sufficiently large and the continuing time of the separation operation is not excessively long are determined as the continuing time of the separation operation. It is possible to automatically determine the continuing time of the separation operation, for example, as a time to reach a value obtained by multiplying a peak value of the number of parts that can be picked up by a predetermined coefficient K. It is preferable to set the coefficient K to a value of, for example, less than one and 0.9 or more.

In step S460, control parameters of the centering command to avoid the interference region Rint are adjusted. The interference region Rint is a region where the gripping mechanism 164 interferes with the outer peripheral wall 414 in the outer periphery portion of the part accommodating region 412 as described with reference to FIG. 12A in the third embodiment. In the adjustment process, for example, the plurality of parts PP are accommodated in the part accommodating region 412, the separation operation (FIG. 4B) is performed, and then the centering operation (step S225 of FIG. 11 and FIG. 12B) for the interference region Rint is executed, and an image acquired by the camera 430 is analyzed to obtain the number of the parts PP that can be picked up. It is preferable to determine whether the picking up is possible by ignoring the front and back of the part PP. It is preferable that the number of parts PP accommodated in the part accommodating region 412 is, for example, the appropriate number of parts determined in step S440. This process is executed respectively under conditions that the continuing time of the centering operation is subsequently changed, and a continuing time during which the number of parts that can be picked up is sufficiently large and the continuing time of the centering operation is not excessively long is determined as the continuing time of the centering operation for avoiding the interference region.

In step S470, control parameters of the flip command are adjusted. In the adjustment process, for example, one part PP is accommodated in the part accommodating region 412, the flip operation (FIG. 4C) by the flip command is performed, and then an image acquired by the camera 430 is analyzed to determine whether the part PP is inverted. This process is executed respectively under conditions that the continuing time of the flip operation is subsequently changed, and a continuing time during which a probability of inverting the part PP is high and the continuing time of the flip operation is not excessively long is determined as the continuing time of the flip operation.

In step S480, control parameters of the feed command are adjusted. In the adjustment process, for example, the plurality of parts PP are accommodated in the part accommodating region 412, the feed operation (FIG. 4A) by the feed command is performed, and then an image acquired by the camera 430 is analyzed to determine the movement amounts of the parts PP. This process is executed respectively under conditions that the continuing time of the feed operation is subsequently changed, and a time during which the movement amounts of the parts PP are appropriate is determined as the continuing time of the feed operation. Alternatively, the continuing time of the feed operation may be determined by obtaining a movement speed [mm/sec] of the parts PP. It is possible to obtain the movement speed [mm/sec] of the parts PP, for example, by accommodating the plurality of parts PP in the part accommodating region 412, performing the feed operation (FIG. 4A) by the feed command for a constant time (for example, one second), and then analyzing an image acquired by the camera 430. Then, it is possible to determine the continuing time of the feed operation by multiplying a distance to be moved by the movement speed.

In step S490, a part replenishment condition by the hopper 500 is determined. In this process, for example, the hopper 500 is operated for a constant time to replenish the part PP to the part accommodating region 412 and an image acquired by the camera 430 is analyzed to obtain the number of replenished parts. This process is executed respectively under conditions that a replenishment time of the hopper 500 is subsequently changed, and a time during which the number of replenished parts PP is appropriate is determined as the replenishment time of the hopper 500. As the number of replenished parts PP, it is preferable to determine both the number of initial replenishments in step S200 of FIG. 6 and the number of replenishments after the second replenishment in step S170. As described above, in the case where the part accommodating region 412 is divided into N412 (N412 is integer of two or more) partitions, the number of replenishments after the second replenishment may be set to the value of 1/(N412−1) of the number of initial replenishments. Alternatively, the part replenishment condition may be determined by obtaining a supply speed [pcs/sec] of the parts PP. For example, the hopper 500 is operated for a constant time (for example, one second) to replenish the part PP to the part accommodating region 412 and an image acquired by the camera 430 is analyzed to obtain the number of replenished parts and the supply speed [pcs/sec] of the parts PP by the hopper 500. Then, it is possible to obtain the replenishment time of the hopper 500 by dividing the number of parts to be supplied by the supply speed.

Various control parameters set as described above are stored in the non-volatile memory 230 (FIG. 2) of the control apparatus 200. The control command in which the part feeder control unit 212 transmits to the part feeder 400 is configured so as to include the control parameters relating to the plurality of vibration actuators 424 among the control parameters set in this manner. In other words, the part feeder control unit 212 selects one or more control commands from the plurality of control commands respectively including the control parameters of the plurality of vibration actuators 424 and transmits the selected control command to the part feeder 400 for causing the part feeder 400 to perform the operation according to the selected control command. Accordingly, it is possible to transmit the control parameters suitable for the operation of the part feeder 400 to the part feeder 400. As a result, it is possible to appropriately operate the part feeder 400 according to the type and the shape of the part PP. Alternatively, it is possible to improve the efficiency of the work of picking up the part PP from the part feeder 400.

The invention is not limited to the embodiments, the examples, and the modification examples described above, and can be realized in various configurations without departing from the spirit of the invention. For example, the technical features in the embodiments, the examples, and the modification examples corresponding to the technical features in each aspect described in the summary section can be replaced or combined as appropriate in order to solve part or all of the problems described above, or to achieve part or all of the effects described above. When the technical feature is not described as an essential feature in this specification, the feature can be deleted as appropriate.

The entire disclosures of Japanese Patent Application Nos. 2017-111275, filed Jun. 6, 2017 and 2017-214446, filed Nov. 7, 2017 are expressly incorporated by reference herein.

INVENTORS:

Kinoshita, Toyotaro, Ishigaki, Toshiyuki

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