CN113195142B

CN113195142B - Automatic welding system, method for manufacturing elevator car chamber member, and automatic welding method

Info

Publication number: CN113195142B
Application number: CN201980084064.5A
Authority: CN
Inventors: 岸本直树; 阿部武司
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2018-12-27
Filing date: 2019-11-07
Publication date: 2022-09-09
Anticipated expiration: 2039-11-07
Also published as: CN113195142A; WO2020137184A1; JP7046226B2; JPWO2020137184A1

Abstract

The automatic welding system is provided with: a data storage unit that stores the order number, the drawing number, and the size data of the welding target workpiece in association with each other; a calculation unit that calculates a welding position of the workpiece to be welded based on the figure number and the size data corresponding to the input result of the order number; an image processing device for calculating an error amount between an actual setting position of the welding target workpiece obtained from the image pickup result of the camera and a standard setting position of the welding target workpiece obtained from the welding position calculated by the calculating part; and a welding machine, wherein the calculation part recalculates the welding position based on the error amount, thereby calculating the welding position after correction, and enabling the welding machine to execute the welding of the welding object workpiece based on the welding position after correction.

Description

Automatic welding system, method for manufacturing elevator car chamber member, and automatic welding method

Technical Field

The present invention relates to an automatic welding system for welding workpieces to be welded, a method for manufacturing an elevator car chamber member, and an automatic welding method.

Background

As a conventional automatic welding system, there is known a system including: NC (Numerical Control) data generated by a CAM (Computer-Aided manufacturing) system is corrected based on CAD (Computer-Aided Design) data including information such as a shape and a mounting position of a work piece, based on a measurement result of a sensor such as a camera with respect to an installation position of the work piece (see, for example, patent documents 1 and 2).

Documents of the prior art

Patent literature

Patent document 1: japanese laid-open patent publication No. 2002-336994

Patent document 2: japanese patent laid-open publication No. 7-230310

Disclosure of Invention

Problems to be solved by the invention

In such an automatic welding system, it is necessary to prepare CAD data in which welding position information of each workpiece is described. However, for example, when the size and the welding position of a panel-shaped member of an elevator vary according to the specifications required by a customer, CAD data needs to be prepared for each specification. Therefore, there is a problem that it takes time and effort to apply the conventional automatic welding system.

Further, when the method of welding by sensing the welding position with a sensor such as a camera is applied to a product such as a large structure having a large number of welding points and a large amount of data, sensing is required for a long time, and there is a problem that productivity cannot be improved.

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide an automatic welding system, a method for manufacturing an elevator car room member, and an automatic welding method, which can improve the workability of welding various workpieces to be welded without preparing CAD data corresponding to each required specification even when the size of the workpiece and the welding position are changed in accordance with the required specification of a customer.

Means for solving the problems

The automatic welding system of the present invention comprises: a server storing the order number, the figure number of the welding object workpiece corresponding to the order number, and size data required for calculating the welding position of the welding object workpiece in association with each other; a computer for calculating a welding position of the welding object workpiece based on the figure number and the size data outputted from the server according to the input result of the order number; a camera capable of photographing a welding position of a welding target workpiece; an image processing device for comparing the actual setting position of the welding target workpiece obtained from the shooting result of the camera with the standard setting position of the welding target workpiece obtained from the welding position calculated by the computer, and calculating the setting error amount which is the difference between the standard setting position and the actual setting position; and a welding machine that welds the welding position calculated by the computer, wherein the computer calculates a corrected welding position by recalculating the welding position based on the setting error amount calculated by the image processing device, and causes the welding machine to perform welding of the welding target workpiece based on the corrected welding position.

The method for manufacturing an elevator car room member according to the present invention is a method for manufacturing an elevator car room member using the automatic welding system according to the present invention, and the workpiece to be welded is any one of a floor, a ceiling, a car door, and a car room wall, which are the elevator car room member.

The automatic welding method of the present invention includes: calculating a welding position of the workpiece to be welded based on the drawing number and the size data outputted from the data storage unit; a step of comparing an actual installation position of the welding target workpiece obtained from an imaging result of a camera capable of imaging the welding position of the welding target workpiece with a standard installation position of the welding target workpiece obtained from the calculated welding position, and calculating an installation error amount which is a difference between the standard installation position and the actual installation position; a step of calculating a corrected welding position by recalculating the welding position based on the calculated setting error amount; and a welding process of causing the welding machine to perform welding of the welding target workpiece based on the corrected welding position.

Effects of the invention

According to the automatic welding system of the present invention, it is possible to obtain an automatic welding system, a manufacturing method of an elevator car room member, and an automatic welding method, which can improve the workability of welding various workpieces to be welded without preparing CAD data corresponding to each required specification even when the size of the workpiece and the welding position are changed in accordance with the required specification of a customer.

Drawings

Fig. 1 is a perspective view of an elevator car room manufactured by a welding method according to embodiment 1 of the present invention.

Fig. 2 is an explanatory view of components of an elevator cage manufactured by the welding method according to embodiment 1 of the present invention.

Fig. 3 is a diagram showing the overall configuration of an automatic welding system according to embodiment 1 of the present invention.

Fig. 4 is a schematic diagram showing another configuration for expanding the extension range of the welding robot in embodiment 1 of the present invention.

Fig. 5 is a schematic diagram showing the exchange of information between the respective components in the automatic welding system according to embodiment 1 of the present invention.

Fig. 6 is a flowchart showing a flow of a series of welding processes in the automatic welding system according to embodiment 1 of the present invention.

Fig. 7 is a diagram showing the relationship between expressions associated with reference numerals in embodiment 1 of the present invention.

Fig. 8 is a schematic diagram showing a specific example of a workpiece to be welded according to embodiment 1 of the present invention.

Fig. 9 is an explanatory diagram showing a specific example of the calculation formula relating to the size, installation position, and welding position of the reinforcing member according to embodiment 1 of the present invention.

Fig. 10 is an explanatory diagram showing a specific example of the calculation formula relating to the size, installation position, and welding position of the reinforcing member according to embodiment 1 of the present invention.

Fig. 11 is a plan view of a welding target workpiece according to embodiment 1 of the present invention.

Fig. 12 is a front view of a welding target workpiece according to embodiment 1 of the present invention.

Fig. 13 is an explanatory diagram in which a part of the welding instruction of embodiment 1 of the present invention is extracted.

Fig. 14 is a schematic diagram of a captured image of the camera according to embodiment 1 of the present invention.

Fig. 15 is an explanatory diagram of a welding position correction method according to embodiment 1 of the present invention.

Fig. 16 is a schematic view of butt welding according to embodiment 2 of the present invention.

Fig. 17 is an explanatory view of welding conditions in embodiment 3 of the present invention.

Fig. 18 is an explanatory view of detailed welding conditions in embodiment 3 of the present invention.

Fig. 19 is a perspective view of a clamping jig according to embodiment 4 of the present invention.

Fig. 20 is an explanatory diagram showing the correspondence between the welding position and the clamping position in embodiment 4 of the present invention.

Detailed Description

Preferred embodiments of an automatic welding system, a method for manufacturing an elevator car room member, and an automatic welding method according to the present invention will be described below with reference to the accompanying drawings.

Embodiment mode 1

Fig. 1 is a perspective view of an elevator car room 400 manufactured by a manufacturing method according to embodiment 1 of the present invention. Fig. 2 is an explanatory view of components of an elevator car room manufactured by the welding method according to embodiment 1 of the present invention. As shown in fig. 1 and 2, the car room 400 is formed by combining a ceiling 401, car doors 402, a car room wall 403, and a floor 404.

Fig. 3 is a diagram showing the overall configuration of an automatic welding system according to embodiment 1 of the present invention. The automatic welding system according to embodiment 1 includes a server 10 as a data storage unit, a computer 20 as a calculation unit, an image processing device 30, and a welding machine 100. Then, the automatic welding system according to embodiment 1 performs welding of the welding target workpiece 200 mounted on the welding stage 300.

Software for calculating the welding position of the welding target workpiece 200 is installed in the computer 20 connected to the server 10. The computer 20 causes the welding machine 100 to perform welding of the welding target workpiece 200 based on the calculated welding position.

The welding machine 100 includes a welding robot 110 as a robot and a robot control device 140 as a control device. A welding torch 120 and a camera 31 are attached to the distal end portion of the manipulator 111 corresponding to the arm of the welding robot 110. As the robot 111, a robot having a 6-axis drive shaft was used. As another example of the configuration, a 7-axis robot or a 3-to 5-axis robot can be used.

The welding robot 110 is provided on the movable stage 130. The position control and the operation control of the welding robot 110, the welding torch 120, the movable mounting table 130, and the camera 31 are performed by the robot control device 140. The robot controller 140 is connected to the computer 20 and the image processing apparatus 30.

The camera 31 is connected to the image processing apparatus 30. The camera 31 can capture an image of the welding target workpiece 200, and the captured image is output to the image processing device 30 as a result of the capture. The image processing device 30 can acquire information of the point group and the outline from the image, and detect the 2-dimensional position or the 3-dimensional position of the welding target workpiece 200 and the posture of the welding target workpiece 200, which are reflected in the image. As the method of such position detection and posture detection, any methods can be used.

The welding robot 110 is disposed so as to be able to weld the welding target workpiece 200 by the welding torch 120 and to be able to capture an image of the welding position of the welding target workpiece 200 by the camera 31.

Here, a case is assumed where the welding target workpiece 200 is a member constituting an elevator. In this case, the workpiece 200 to be welded is a large structure having a side of several meters at most, and the entire workpiece 200 to be welded cannot be welded in the extension range of the normal welding robot 110.

Therefore, in fig. 3, the welding robot 110 is provided on a movable stage 130 that can move the entire welding robot 110 in a direction perpendicular to the paper surface. With such a configuration, the extension range of the welding robot 110 can be extended, and the welding torch 120 can weld the entire workpiece 200 to be welded.

Fig. 4 is a schematic diagram showing another configuration for expanding the extension range of the welding robot 110 in embodiment 1 of the present invention. As shown in fig. 4, by suspending the welding robot 110 from a structure 131 that can move similarly to a crown block that can move in the horizontal 2 direction, a larger welding target workpiece 200 can be welded.

Next, a series of flows of automatic welding in the automatic welding system according to embodiment 1 will be described with reference to fig. 5 and 6. Fig. 5 is a schematic diagram showing the exchange of information between the respective components in the automatic welding system according to embodiment 1 of the present invention. Fig. 5 shows the components of the server 10, the computer 20 with welding position calculation software installed, the image processing device 30 connected to the camera 31, and the welding machine 100. These components are connected by a wired cable, a radio wave, or the like. As a result, the automatic welding system according to embodiment 1 is configured with a local area network.

Fig. 6 is a flowchart showing a flow of a series of welding processes performed by the automatic welding system according to embodiment 1 of the present invention. The following describes the operation sequence of welding in embodiment 1, with reference to the exchange of information between the components shown in fig. 5 and the flowchart shown in fig. 6.

First, in step S601, an order number for specifying the welding target workpiece 200 is read by the barcode reader. Then, the read order number is transmitted to the server 10.

In the server 10, the order number, the drawing number of the welding object workpiece 200 corresponding to the order number, and the size data required for calculating the welding position of the welding object workpiece 200 are stored in association. In the following description, the vertical and horizontal dimensions of the welding target workpiece 200 are stored in the server 10 as dimensional data necessary for calculating the welding position.

After the order number is transmitted from the barcode reader to the server 10, in step S602, the server 10 extracts the figure number and the vertical size and the horizontal size as the size data according to the input result of the order number. Further, in step S603, the server 10 transmits the extracted drawing number, vertical size, and horizontal size to the computer 20.

In the computer 20, a calculation formula for calculating the welding position from the data of the longitudinal dimension and the lateral dimension is installed as welding position calculation software in accordance with each drawing number. That is, in the welding position calculation software, parameters necessary for calculation of the welding position are the longitudinal dimension and the lateral dimension of the welding object workpiece 200. Therefore, in step S604, the computer 20 can calculate the welding position of the welding target workpiece 200 by substituting the vertical dimension and the horizontal dimension received from the server 10 into the calculation formula corresponding to the reference numeral.

Next, in step S605, the computer 20 transmits a movement command including information of the calculated welding position to the robot controller 140, and the robot controller 140 operates the robot hand 111 and captures an image of the welding position using the camera 31. Next, in step S606, the image processing apparatus 30 acquires image data captured by the camera 31. Further, the image processing device 30 calculates an installation error amount which is a difference between the standard installation position and the actual installation position of the welding target workpiece 200.

Here, image processing device 30 can calculate a position to be originally set on welding target workpiece 200 as a standard set position based on the welding position calculated by computer 20. Further, the image processing device 30 can calculate the position where the welding target workpiece 200 is actually set as the actual setting position by performing image processing on the image data acquired from the camera 31. Then, the image processing apparatus 30 transmits the setting error amount calculated as the difference between the standard setting position and the actual setting position to the computer 20.

Next, in step S607, the computer 20 compares the setting error amount with a predetermined allowable error amount. Then, the computer 20 determines whether or not the setting error amount is less than or equal to the allowable error amount, and proceeds to the next step S608 when the setting error amount is less than or equal to the allowable error amount.

On the other hand, when the setting error amount exceeds the allowable error amount, the computer 20 notifies an error to urge the operator to move the welding target workpiece 200 to a correct position.

In the case of proceeding to step S608, the computer 20 recalculates the welding position based on the setting error amount calculated by the image processing apparatus 30, thereby calculating the corrected welding position. That is, the computer 20 recalculates the welding position that is shifted in consideration of the setting error amount as the welding position after correction.

Finally, in step S609, computer 20 transmits the recalculated corrected welding position to robot control device 140, and starts automatic welding by welding robot 110.

Next, details of each step shown in fig. 6 will be described with reference to fig. 7 to 16. First, step S601 to step S603 will be described in detail. Fig. 7 is a diagram showing the relationship between expressions associated with reference numerals in embodiment 1 of the present invention. Reference numerals a to C shown in fig. 7 are reference numerals of the workpiece 200 to be welded. The drawing data that becomes the standard is stored in the storage device of the computer 20. As shown in fig. 7, the welding target workpiece 200 is given a plurality of reference numerals according to its kind.

Further, in each drawing, the reinforcement length, the number of reinforcements, the inter-reinforcement pitch, and each calculation formula relating to the welding position are given in relation to the reinforcement member. The respective calculation formulas associated with the reference numerals as shown in fig. 7 are stored in the computer 20 as welding position calculation software.

The parameters of these calculation formulas are defined by the longitudinal dimension and the lateral dimension of the welding target workpiece 200. Therefore, the computer 20 can calculate the welding position by knowing the drawing number, the vertical dimension, and the horizontal dimension of the workpiece 200 to be welded. Therefore, it is not necessary to input information about the welding position of the reinforcing member to the computer 20. Alternatively, CAD data reflecting the size data and the welding position need not be created for each specification required by a changing customer.

As described above, the drawing number, the vertical dimension, and the horizontal dimension corresponding to the welding target workpiece 200 are stored in the server 10 in association with the order number. Therefore, for example, by reading a barcode or the like used for tracking of the production line to acquire an order number and by making the server 10 compare the read order number, the computer 20 can acquire a drawing number, a vertical dimension, and a horizontal dimension corresponding to the welding target workpiece 200.

Of course, the order number may be acquired by a known method other than reading a barcode, or a tracking code other than a barcode may be used.

Next, step S604 in fig. 6 will be described in detail. Fig. 8 is a schematic diagram showing a specific example of the welding target workpiece 200 according to embodiment 1 of the present invention. Here, a method of calculating a welding position will be described with respect to a case where the reinforcing member 202 is welded to the exterior panel 201, taking the welding target workpiece 200 shown in fig. 8 as an example. The exterior panel 201 and the reinforcing member 202 correspond to the welding target workpiece 200.

As described with reference to fig. 7, the calculation formula is indicated in the drawing with the dimension of the reinforcing member 202 with respect to the welding position as a variable. The calculation is stored as welding position calculation software. Fig. 9 and 10 are explanatory diagrams showing a specific example of the calculation formula relating to the size, the installation position, and the welding position of the reinforcing member 202 according to embodiment 1 of the present invention. Examples of the calculation formula stored as the welding position calculation software include calculation formulas shown in fig. 9 and 10.

In the calculation formula illustrated in fig. 9, the length and the number of welds of the reinforcing member are the drawing variables Z and are described by the vertical dimension a of the exterior panel 201. As shown in fig. 10, the number N of reinforcing members 202 and the pitch length Q between the reinforcing members 202 are also variables in the drawing, and are described by the lateral dimension B of the exterior panel 201.

Fig. 11 is a plan view of a welding target workpiece 200 according to embodiment 1 of the present invention. Fig. 12 is a front view of a welding target workpiece 200 according to embodiment 1 of the present invention. Fig. 13 is an explanatory diagram in which a part of the welding instruction in embodiment 1 of the present invention is extracted. This is a weld mark called fillet welding. The boundary part of the reinforcing plate and the decorative plate at the arrow end part of the drawing is welded. The numerals in the weld marks shown in fig. 13 specifically mean that the near-front side fillet length is 3mm, the weld length is 50mm, the number of welds Z is 3, and the pitch is 200 mm. As an example here, the drawing variables of fig. 9 are associated with the number of welds.

The computer 20 can derive the length of the reinforcing members 202, the number of welds, the number N of the reinforcing members 202, and the pitch length Q between the reinforcing members 202 from the calculation formulas shown in fig. 9 and 10. As a result, the computer 20 can specify the dimensions shown in fig. 11 and 12, and can specify the welding position.

Next, step S605 to step S607 in fig. 6 will be described in detail. Here, a case in which the outer appearance panel 201 and the reinforcing member 202(a) in fig. 11 are the welding target workpiece 200 will be described as an example.

As shown in fig. 11, the lower left corner of the appearance panel 201 is set as the origin O, the lateral direction is set as the x-axis, and the vertical direction is set as the y-axis. Next, the camera 31 photographs the lower left portion G and the upper left portion H of the reinforcing member 202 (a). Here, with respect to the origin O, the standard xy coordinates of the lower left G are G (a, b), and the standard xy coordinates of the upper left H are H (a, b + Z1).

Fig. 14 is a schematic diagram of a captured image of the camera 31 in embodiment 1 of the present invention. Specifically, (a) in fig. 14 shows an image of the lower left portion G, and (b) in fig. 14 shows an image of the upper left portion H. The image processing device 30 acquires an image captured by the camera 31 as shown in fig. 14. The image processing apparatus 30 obtains the contour by performing edge extraction processing on the exterior panel 201 and the reinforcement member 202(a) based on the acquired image. Then, the image processing apparatus 30 obtains the coordinates of the lower left portion G and the upper left portion H of the reinforcement member 202 (a).

The image processing apparatus 30 acquires the position coordinates G (a, b) and H (a, b + Z1) calculated by the computer 20 according to the calculation formula as standard installation positions. The image processing device 30 performs the above-described image processing on the image acquired by the camera 31, thereby calculating the position coordinates G (a + δ a, b + δ b) and H (a + δ a ', b + Z1+ δ b') as actual installation positions, as shown in fig. 14.

Therefore, the image processing apparatus 30 can determine δ a, δ b, δ a ', and δ b' as the setting error amount by obtaining the difference between the position coordinates G (a, b) and H (a, b + Z1) as the standard setting positions and the position coordinates G (a + δ a, b + δ b) and H (a + δ a ', b + Z1+ δ b') as the actual setting positions. When these set error amounts exceed the allowable error amount, the error is terminated.

Similarly, the image processing apparatus 30 calculates the set error amount of each reinforcement member 202 based on the images of the lower left portion and the upper left portion of the reinforcement members 202(b), 202(c), 202(d), and 202(e) captured by the camera 31, and determines whether or not the set error amount exceeds the allowable error amount. In addition, when an error determination is made, the operator can promptly take necessary measures by notifying that the installation position exceeds the allowable error amount for any of the reinforcement members. The error determination and the notification process associated with the error can be performed by the computer 20 that has received the set error amount.

Finally, step S608 and step S609 of fig. 6 will be described in detail. Fig. 15 is an explanatory diagram of a welding position correction method according to embodiment 1 of the present invention. For example, as shown in fig. 15, a method of calculating a corrected welding position based on the setting error amount will be described for a case where the reinforcing member 202 is disposed at an actual installation position indicated by a solid line while deviating from a standard installation position indicated by a two-dot chain line.

First, the image processing apparatus 30 transmits the setting error amounts δ a, δ b, δ a ', δ b' calculated in step S606 to the computer 20. Based on the received setting error amount, computer 20 recalculates the trajectory of welding torch 120 according to the following calculation formula, thereby calculating the corrected welding position.

Formula 1

x＝{y-(b+δb)}×tanθ+(a+δa)

(b+δb)≤y≤(b+z1+δb′)

The welding start point and the welding end point are linear. Therefore, the computer 20 can create a welding line in consideration of the error amount by performing linear compensation from the position indicated by the 2 nd point (vertical line). Therefore, the computer 20 can supplement the welding position even when the position during welding becomes a blind spot of the camera 31. The computer 20 can similarly determine the weld line of the other reinforcing members 202. Therefore, the computer 20 can cause the robot control device 140 to perform welding of the welding robot 110 to the welding target workpiece 200 by transmitting the data to the robot control device 140.

As described above, according to embodiment 1, the welding position is photographed by the camera before actual welding, and the setting error amount of the welding target workpiece is calculated by the image processing device using the photographing result, whereby the position and trajectory data of the welding torch obtained by off-line teaching based on the drawing number and the size data can be corrected. As a result, it is possible to cope with the installation error of each workpiece and the variation of the workpiece itself, and to improve the welding accuracy.

Further, the welding position of the reinforcing member can be automatically calculated by a calculation formula. Therefore, it is not necessary to mark the welding position in advance, and it is also not necessary for the operator to manually input the welding position. Therefore, welding errors can be reduced, and an operator is not required, so that there is an advantage that workability is improved and labor cost can be reduced.

Therefore, the automatic welding system according to embodiment 1 can be easily applied to, for example, a panel-shaped member of an elevator, even when the size and welding position of a workpiece are changed in accordance with the specifications required by a customer.

Embodiment mode 2

In embodiment 1, a description has been given of a mode in which 2 points, that is, a welding start point and a welding end point, are photographed by using the camera 31, and a welding position is corrected by using the photographed 2 points. However, the number of points used for correction is not limited to 2 points, and may be increased to 3 points or more. Therefore, in embodiment 2, a case will be described where welding position correction processing is performed based on a recognition result of 3 points or more.

Fig. 16 is a schematic view of butt welding according to embodiment 2 of the present invention. For example, as shown in fig. 16, when welding member 210(a) and welding member 210(b) are butt-welded using laser beam 122, the effect of performing the welding position correction processing based on the recognition result of 3 or more points is exhibited.

A case where the laser beam 122 irradiated from the optical head 121 is irradiated to the boundary 211 between the welding member 210(a) and the welding member 210(b) to perform welding is considered. In this case, if the focal diameter of the laser beam 122 is small and the focal point of the laser beam 122 is deviated from the boundary 211, the welding strength is greatly reduced, and if the deviation width is large, welding cannot be performed. Therefore, the focal position of the laser beam 122 needs to follow the boundary portion 211 with high accuracy. In such a case, the accuracy of the welding position can be improved by increasing the number of recognition sites for correction to 3 or more.

Embodiment 3

In each of embodiments 1 and 2 described above, a case where the actual installation position of the welding target workpiece 200 is obtained using the camera 31 is described. However, the actual installation position of the welding target workpiece 200 may be determined using a laser sensor, an ultrasonic sensor, a contact type distance sensor, or the like, in addition to the camera 31. The camera 31 or the sensor described above need only be capable of acquiring information on the actual installation position of the welding target workpiece 200, and need not necessarily be mounted on the welding robot 110.

In the above embodiments 1 and 2, the case where the arc welding operation and the laser welding operation are applied is described. However, other work robots can also be used as application objects.

For example, the present invention may be applied to an application in which a welding electrode is attached to a robot instead of the welding torch 120 to perform spot welding. Further, instead of the welding torch 120, a grinder may be mounted on a robot for deburring or for use in removing burrs.

The workpiece to be applied is not limited to the welding target member of the elevator, and any workpiece can be applied as long as the welding position is specified by the calculation formula based on the outer diameter shape of the workpiece. In particular, by applying the system structure of the present invention to a plurality of kinds of small-volume products, a great effect can be achieved.

In embodiments 1 to 3, a case where a calculation formula is used to calculate the welding position of the workpiece to be welded from the drawing number and the size data is described. However, instead of the calculation formula, a configuration may be adopted in which the welding position of the welding target workpiece is calculated using a function with the reference number and the size data as parameters or a table with the reference number and the size data as parameters.

In addition to the drawing numbers and the size data, the data of the material and the plate thickness of the welding target workpiece is transmitted from the server 10 to the computer 20, whereby the welding conditions can be automatically selected.

Fig. 17 is an explanatory view of welding conditions in embodiment 3 of the present invention. Fig. 18 is an explanatory diagram of detailed welding conditions in embodiment 3 of the present invention. Specifically, as shown in fig. 17 and 18, welding conditions corresponding to the materials and the plate thicknesses prepared in advance are automatically selected and welding is performed. This can be applied even when the material type and the sheet thickness are changed in accordance with the customer specification.

Embodiment 4

Fig. 19 is a perspective view of a clamping jig according to embodiment 4 of the present invention. The clamp 301 for a workpiece to be welded is composed of a table 302, a beam 303, and a clamp portion 304. By preparing a clamping position calculation formula using the reference numeral and the size data as parameters in the computer 20, the clamping position can be automatically adjusted according to the size and the set position of the workpiece to be welded.

This enables automation of the clamping position adjustment step before welding. The clamping portion 304 of the clamping jig 301 is formed of, for example, an air cylinder, and clamps the workpiece to be welded by pressing the workpiece. The beam 303 and the clamp 304 are configured by, for example, a ball screw and a linear guide so as to be movable in the x-axis direction and the y-axis direction.

Fig. 20 is an explanatory view showing the correspondence between the welding position and the clamping position in embodiment 4 of the present invention. As shown in fig. 20, by automatically moving the position of the clamp portion 304, the portion closest to the welding position calculated by the computer 20 is always clamped, so that the gap between the exterior panel 201 and the reinforcing member 202 can be minimized, and the welding quality can be improved.

Description of reference numerals

10 server, 20 computer, 30 image processing device, 31 camera, 100 welding machine, 110 welding robot, 111 robot, 120 welding torch, 130 movable table, 140 robot control device, 200 welding object workpiece, 201 appearance panel, 202 reinforcing member, 301 clamping jig, 302 table, 303 beam, 304 clamping part, 305 welding torch, 400 car room, 401 ceiling, 402 car door, 403 car room wall, 404 floor.

Claims

1. An automatic welding system, wherein,

the automatic welding system is provided with:

a data storage unit that stores a drawing number of a welding target workpiece and size data required for calculating a welding position of the welding target workpiece in association with each other;

a calculation unit that calculates a welding position of the welding target workpiece;

a camera capable of photographing the welding position of the welding target workpiece;

an image processing device that compares an actual installation position of the welding target workpiece obtained from the imaging result of the camera with a standard installation position of the welding target workpiece obtained from the welding position calculated by the calculation unit, and calculates an installation error amount that is a difference between the standard installation position and the actual installation position; and

a welding machine for welding the welding position calculated by the calculation unit,

the standard drawing corresponding to the drawing number contains a calculation for deriving drawing variables relating to the welding location from the dimensional data,

the calculating part

Calculating the welding position of the welding object workpiece based on the drawing variables corresponding to the drawing numbers output from the data storage section and the size data,

calculating a corrected welding position by recalculating the welding position based on the setting error amount calculated by the image processing device,

and causing the welding machine to perform welding of the welding object workpiece based on the corrected welding position.

2. The automatic welding system of claim 1,

the workpiece to be welded is a workpiece formed by welding a first member and a plurality of second members,

the drawing variables include any one of a length of the second members, the number of welds of the second members, and a length of a space between the second members.

3. The automated welding system of claim 2,

the setting error amount is calculated from the coordinates of the first member and the coordinates of the second member.

4. The automatic welding system of claim 2 or 3,

the first member is a panel member that is,

the second member is a reinforcing member.

5. The automatic welding system of claim 4,

the image processing apparatus calculates respective setting error amounts of the reinforcement members, and determines whether or not the setting error amounts exceed allowable error amounts.

6. The automatic welding system of any of claims 1, 2, 3, 5,

the data storage unit stores material data of the welding target workpiece, and the calculation unit determines a welding condition of the welding target workpiece based on the material data.

7. The automatic welding system of any of claims 1, 2, 3, 5,

the welding machine has:

a robot having a welding torch mounted on a distal end portion thereof and having at least 3 drive shafts; and

and a control device for performing welding of the workpiece to be welded by performing position control of the robot based on the corrected welding position received from the calculation unit.

8. The automated welding system of claim 7,

the welding machine further comprises a movable loading platform which is provided with the robot and can make the whole robot move,

the control device performs position control of the robot and the movable stage based on the corrected welding position received from the calculation unit, thereby performing welding of the welding target workpiece.

9. The automated welding system of claim 7,

the camera is mounted on the robot and is mounted on the robot,

the calculation unit outputs a movement command to the control device to move the robot to a position where the welding position can be imaged,

the control device controls the position of the robot based on the movement command, images the welding position by the camera,

the image processing device calculates the setting error amount using an imaging result of the camera mounted on the robot with respect to the welding position.

10. The automated welding system of any of claims 1, 2, 3, 5, 8, 9,

the camera photographs 2 points of a welding start point and a welding end point included in the welding position,

the image processing device calculates the setting error amount based on a result of photographing with respect to the welding start point and a result of photographing with respect to the welding end point.

11. A method of manufacturing an elevator cage room member using the automatic welding system according to any one of claims 1 to 10,

the workpiece to be welded is any one of a floor, a ceiling, a car door, or a car chamber wall as an elevator car chamber member.

12. An automatic welding method, wherein,

the automatic welding method comprises:

calculating a welding position of the welding target workpiece using a calculation formula for deriving a drawing variable related to the welding position based on the drawing number and the dimension data output from the data storage unit;

a step of comparing an actual installation position of the welding target workpiece obtained from an imaging result of a camera capable of imaging the welding position of the welding target workpiece with a standard installation position of the welding target workpiece obtained from the calculated welding position, and calculating an installation error amount which is a difference between the standard installation position and the actual installation position;

a step of calculating a corrected welding position by recalculating the welding position based on the calculated setting error amount; and

and a welding step of causing a welding machine to perform welding of the welding target workpiece based on the corrected welding position.