TOOL SYSTEM

A tool system includes an image capturing unit, a storage unit, a class identifier, and a spot determiner. The image capturing unit shoots a work spot of a target article and thereby generates captured image data. The storage unit stores a plurality of reference image data items with the plurality of reference image data items classified into multiple groups according to respective classes of the plurality of articles. The class identifier acquires identification information to identify the class of the target article. The spot determiner determines the work spot shot by the image capturing unit by comparing the captured image data with one of the plurality of reference image data items, which belongs to one of the multiple groups that is associated with the class of the target article identified by reference to the identification information.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is based upon, and claims the benefit of priority to, Japanese Patent Application No. 2022-011290, filed on Jan. 27, 2022, the entire disclosure of which is hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure generally relates to a tool system and more particularly relates to a tool system including an image capturing unit.

BACKGROUND ART

JP 2021-074810 A discloses a tool system including a tool, a storage unit, an image capturing unit, and a processing unit. The storage unit stores a plurality of reference images corresponding to a plurality of work targets, respectively. The image capturing unit is provided for the tool to generate a captured image. The processing unit performs image processing of comparing the captured image shot by the image capturing unit with the plurality of reference images, thereby identifying an actually shot work target, which is a work target shot in the captured image, out of a plurality of work targets. The shooting condition for the plurality of reference images is different from the shooting condition for the captured image.

A tool system of the type disclosed in JP 2021-074810 A is sometimes required to speed up the processing of determining the work spot (corresponding to the actually shot work target).

SUMMARY

The present disclosure provides a tool system with the ability to speed up the processing of determining the work spot.

A tool system according to an aspect of the present disclosure includes a driving unit, a working part, an image capturing unit, a storage unit, a class identifier, and a spot determiner. The driving unit is activated with power supplied from a power source. The working part is driven by the driving unit to perform work on a work spot of a target article. The image capturing unit shoots the work spot and thereby generates captured image data. The storage unit stores a plurality of reference image data items with the plurality of reference image data items classified into multiple groups according to respective classes of a plurality of articles. The plurality of reference image data items correspond to respective models of work spots of the plurality of articles. The class identifier acquires identification information to identify the class of the target article. The spot determiner determines the work spot shot by the image capturing unit by comparing the captured image data with one of the plurality of reference image data items, which belongs to one of the multiple groups that is associated with the class of the target article identified by reference to the identification information.

DETAILED DESCRIPTION

Embodiment

A tool system according to an exemplary embodiment will now be described with reference to the accompanying drawings. Note that the embodiment to be described below is only an exemplary one of various embodiments of the present disclosure and should not be construed as limiting. Rather, the exemplary embodiment may be readily modified in various manners depending on a design choice or any other factor without departing from the scope of the present disclosure. The drawings to be referred to in the following description of embodiments are all schematic representations. Thus, the ratio of the dimensions (including thicknesses) of respective constituent elements illustrated on the drawings does not always reflect their actual dimensional ratio.

Overview

A tool system1according to this embodiment as shown inFIG.1may be used in the process of manufacturing a target article W1(article of manufacture) at a factory, for example. The tool system1includes a tool block3, which may be an electric tool such as an impact wrench and which includes a working part32such as a socket or a wrench bit. The working part32is a part for use to perform work on a predetermined work spot, which is one of a plurality of work spots T1-T4(refer toFIG.3) of a target article W1. Each of the plurality of work spots T1-T4is a particular part of the target article W1. The worker performs a predetermined type of work on the predetermined work spot of the target article W1by using this tool system1.

In addition, the tool system1also includes an image capturing unit41that shoots a work spot and thereby generates captured image data. The tool system1determines, based on the captured image data, the work spot that has been shot by the image capturing unit41. In addition, the tool system1also controls the operation of the working part32according to the work spot determined. The tool system1may be scheduled, for example, to perform work on the plurality of work spots T1-T4following a predetermined procedure. When finding the work spot determined based on the captured image data conforming to the procedure, the tool system1allows the working part32to operate. On the other hand, when finding the work spot determined not conforming to the procedure, the tool system1prohibits the working part32from operating.

Also, the tool system1performs work on target articles W1of multiple classes at a factory. As used herein, the “class” of a target article W1refers to, for example, the model number, the product number, or the manufacturing lot number of the target article W1. The tool system1has the function of determining (identifying) the class of the target article W1.

For example, if the tool system1is used at a car factory and the target article W1is a car or a car component, then the class of the target article W1may be, for example, a combination of a car model and its body color, or its product number. Alternatively, if the tool system1is used at a car factory and the target article W1is a car component, then the class of the target article W1may be, for example, a combination of information indicating what the target article W1is (e.g., a bumper, a hood (or bonnet), or a door), a car model, and its body color.

As shown inFIG.1, the tool system1according to this embodiment includes a driving unit31, the working part32, the image capturing unit41, a storage unit11, a class identifier53, and a spot determiner54. The driving unit31is activated with power supplied from a power source201. The working part32is driven by the driving unit31to perform work on a work spot of a target article W1. The image capturing unit41shoots the work spot and thereby generates captured image data. The storage unit11stores a plurality of reference image data items with the plurality of reference image data items classified into multiple groups according to respective classes of the plurality of articles. The plurality of reference image data items correspond to respective models of work spots of the plurality of articles. The class identifier53acquires identification information to identify the class of the target article W1. The spot determiner54determines the work spot shot by the image capturing unit41by comparing the captured image data with one of the plurality of reference image data items, which belongs to one of the multiple groups that is associated with the class of the target article W1identified by reference to the identification information.

According to this embodiment, the spot determiner54determines the work spot by using a reference image data item belonging to a group (hereinafter referred as a “target group”) associated with the class of the target article W1. That is to say, the spot determiner54may determine the work spot without using reference image data items not belonging to the target group. This enables speeding up the processing of determining the work spot, compared to using all reference image data items. In addition, this also reduces the chances of the spot determiner54determining, by mistake, a work spot, associated with a reference image data item not belonging to the target group, to be a work spot on which the work is going to be performed.

Details

The tool system1may be used, for example, in an assembly line for performing assembling work on articles of manufacture at a factory. In particular, in this embodiment, the tool block3included in the tool system1is supposed to be a fastening tool such as an impact wrench for use to tighten a fastening member (such as a bolt or a nut). Specifically, this embodiment is supposed to be applied to a situation where a single article of manufacture has a plurality of portions to be fastened (work spots T1-T4, refer toFIG.3), thus requiring the worker to attach a fastening member onto each of those portions to be fastened by using the tool block3in a single workplace.

As used herein, the “portion to be fastened” refers to a part of a workpiece (target article W1), to which the fastening member is going to be attached. For example, if the fastening member is a bolt, then the portion to be fastened is an area surrounding, and covering, a screw hole to which the fastening member is attached. That is to say, in this embodiment, a single workpiece has a plurality of such portions to be fastened.

As used herein, the “target article” refers to an article on which work is supposed to be performed by using the tool block3.

As used herein, the “captured image data” refers to the electronic data of an image captured by the image capturing unit41and includes a still picture (still image) and a moving picture (motion picture). The “moving picture” further includes a group of still pictures captured by stop-motion shooting, for example. The captured image data does not have to be output data itself provided by the image capturing unit41. For example, the captured image data may have been subjected, as needed, to data compression, conversion into another data format, cropping an image portion from the image captured by the image capturing unit41, focus adjustment, brightness adjustment, contrast adjustment, or any of various other types of image processing. Alternatively, the captured image data may also be data representing a feature quantity extracted from the output data of the image capturing unit41. In this embodiment, the output data of the image capturing unit41is supposed to be full-color still picture data, for example. In addition, in this embodiment, the captured image data is supposed to be used after having been converted into a feature quantity.

(2) Overall Configuration

As shown inFIG.1, the tool system1according to this embodiment includes the tool block3, a camera block4, a processing unit5, the storage unit11, a communications unit12, and the power source201. The tool system1communicates with a high-order system6(wireless device D1) and a tag7(wireless device D2) wirelessly. The tag7is an attachment of the target article W1.

(3) Tool Block

The tool block3shown inFIGS.1and2is a portable one. The tool block3includes a body2, the driving unit31, and the working part32.

In this embodiment, the tool block3is an electric tool configured to activate the working part32by using electrical energy. In particular, in this embodiment, the tool block3is supposed to be an impact wrench. Such a tool block3may be used to perform fastening work of attaching a fastening member onto the target article W1.

Also, the power source201according to this embodiment is a battery pack. The driving unit31is activated with motive power (e.g., electrical energy) supplied from the power source201. That is to say, the driving unit31drives the working part32with the motive power supplied from the power source201. In this embodiment, the power source201is supposed to be counted among the constituent elements of the tool system1. However, the power source201does not have to be one of the constituent elements of the tool system1.

The driving unit31includes a motor. In this embodiment, the motor is supposed to be an electric motor. The driving unit31further includes, for example, a transmission mechanism and an output shaft311(refer toFIG.2). The transmission mechanism includes a plurality of gears and an impact mechanism. The transmission mechanism transmits the kinetic energy of the motor to the output shaft311. That is to say, the output shaft311turns around a rotational axis Ax1, which is aligned with the direction in which the output shaft311protrudes, as the motor runs. In other words, as the motor runs, torque is applied to the output shaft311, thereby causing the output shaft311to turn.

The working part32is held by the output shaft311. The working part32receives the kinetic energy from the motor and performs work on the target article W1. The working part32according to this embodiment is a socket. The working part32turns after having been fitted onto a fastening member. Thus, the fastening member turns along with the working part32, thus having the work of tightening or loosening the fastening member into/from the target article W1done.

Optionally, a socket anvil may also be attached, instead of the working part32, onto the output shaft311. If the socket anvil is attached to the output shaft311, a working part32such as a bit (such as a screwdriver bit or a drill bit) may be attached to the output shaft311via the socket anvil.

As shown inFIG.2, the body2includes a barrel21, a grip22, and an attachment member23. The barrel21is formed in a cylindrical shape (e.g., circular cylindrical shape in this embodiment). The grip22protrudes along a normal to a part of the circumferential surface of the barrel21(i.e., along the radius of the barrel21). To the attachment member23, the power source201is attached removably. In this embodiment, the attachment member23is provided at the tip of the grip22. In other words, the barrel21and the attachment member23are coupled together via the grip22.

In the body2, housed are a part of the driving unit31(namely, its motor and transmission mechanism, for example) and a part of the image capturing unit41. In addition, the processing unit5(refer toFIG.1), the storage unit11, and the communications unit12are also housed in the body2. That is to say, in this embodiment, the image capturing unit41, the processing unit5, the storage unit11, and the communications unit12, which are constituent elements of the tool system1, are housed in the body2and thereby integrated with the tool block3. At least a part of the driving unit31is housed in the barrel21.

The grip22is a part to be gripped by the worker while he or she is performing the work using the tool system1. The tool block3further includes a trigger switch221and a forward/reverse switch222provided for the grip22. The trigger switch221is a switch for controlling the ON/OFF states of the operation performed by the driving unit31and allows adjusting the number of revolutions of the output shaft311according to how deep the trigger switch221is pulled. The forward/reverse switch222is a switch for switching the rotational direction of the output shaft311from the clockwise direction to the counterclockwise direction, and vice versa.

The attachment member23is formed in the shape of a compressed rectangular parallelepiped. The power source201is attached removably to one side, opposite from the grip22, of the attachment member23.

The power source201(battery pack) includes a case202made of a resin and formed in a rectangular parallelepiped shape. The case202houses a rechargeable battery (such as a lithium-ion battery) inside. The power source201supplies electric power to the driving unit31, the processing unit5, the image capturing unit41, and other constituent members.

The tool block3further includes an operating panel231provided for the attachment member23. The operating panel231may include a plurality of press button switches232and a plurality of LEDs (light-emitting diodes)233, for example. The operating panel231allows the worker to enter various types of settings for, and confirm the state of, the tool block3. That is to say, by operating the press button switches232of the operating panel231, the worker may change the operation mode of the tool block3or check the remaining capacity of the power source201, for example.

The tool block3further includes a light-emitting unit234provided for the attachment member23. The light-emitting unit234includes an LED, for example. The light-emitting unit234emits light toward the target article W1while the worker is performing work using the tool block3. The light-emitting unit234may be turned ON and OFF by operating the operating panel231. Alternatively, the light-emitting unit234may also be lit automatically when the trigger switch221turns ON.

(4) Camera Block

As shown inFIG.1, the camera block4includes the image capturing unit41.

As shown inFIG.2, the image capturing unit41is provided for the tool block3and generates captured image data. The image capturing unit41may be implemented as a camera including an image sensor and a lens, for example. The image sensor may be a two-dimensional image sensor such as a charge-coupled device (CCD) image sensor or a complementary metal-oxide semiconductor (CMOS) image sensor.

In this embodiment, the image capturing unit41may be housed in (the barrel21of) the body2of the tool block3and thereby provided for the tool block3integrally with the tool block3. The image capturing unit41is provided to be oriented toward the tip of the output shaft311to capture an image of the target article W1while the worker is performing the work using the tool block3. InFIG.3, the shaded part indicates an image capturing range of the image capturing unit41.

In response to the worker pulling the trigger switch221or operating the operating panel231, for example, the image capturing unit41captures an image within its image capturing range, thereby generating captured image data.

(5) Storage Unit

The storage unit11is housed in the body2of the tool block3. Examples of the storage unit11include a read-only memory (ROM), a random-access memory (RAM), and an electrically erasable programmable read-only memory (EEPROM).

The storage unit11stores a plurality of reference image data items (i.e., multiple items of reference image data) with the plurality of reference image data items classified into multiple groups according to respective classes of the plurality of articles. That is to say, the storage unit11stores the plurality of reference image data items themselves and information for use to classify the plurality of reference image data items into multiple groups (hereinafter referred to as “classification information”). The plurality of reference image data items and the classification information may be stored in advance in the storage unit11, provided by either the wireless device D1or the wireless device D2, downloaded via a telecommunications line such as the Internet, or distributed after having been stored in a non-transitory storage medium such as a memory card.

Note that the “plurality of articles” as used herein includes an article to be subjected to the same type of work as the one currently performed on the target article W1. Examples of such an article, on which the same type of work as the one currently performed on the target article W1is supposed to be performed, include an article having the same model number or product number as the target article W1. In addition, the plurality of articles further includes, for example, an article to be subjected to a different type of work from the one currently performed on the target article W1.

The reference image data is data corresponding to the model of a work spot of an article. More specifically, the model of the work spot of the article is a model for classifying the captured image data (image classification models). The reference image data may be original data generated by shooting the work spot of the article or data subjected to some type of image processing as needed, whichever is appropriate. In the following description of embodiments, a situation where the reference image data is the feature quantity of the work spot of the article will be described as an example. The reference image data may be, for example, a feature quantity extracted from predetermined image data by using a convolutional neural network. The predetermined image data may be generated by shooting an article using a predetermined device (such as the camera block4or any other device).

The reference image data may include, as error data, data generated by shooting at least one of a spot, other than the work spot, of the article or the environment surrounding the article. If the captured image data turns out to match the error data, then the spot that has been shot is determined to be erroneous as the work spot.

(6) Communications Unit

The communications unit12is housed in the body2of the tool block3. The communications unit12includes a communications interface device. The communications unit12is ready to communicate with the wireless device D1, D2via the communications interface device. As used herein, the phrase “be ready to communicate” refers to a state where the device is ready to transmit and receive signals either directly or indirectly via a network or a relay, for example, in compliance with an appropriate communications protocol for wired or wireless communication. The communications unit12according to this embodiment communicates wirelessly with the wireless device D1, D2in compliance with a protocol suitable for short-range wireless communication such as the protocol for use in Bluetooth®.

(7) Processing Unit

The processing unit5includes a computer system including one or more processors and a memory. At least some of the functions of the processing unit5are performed by making the processor of the computer system execute a program stored in the memory of the computer system. The program may be stored in the memory. The program may also be downloaded via a telecommunications line such as the Internet or distributed after having been stored in a non-transitory storage medium such as a memory card.

As shown inFIG.1, the processing unit5includes an image capturing controller51, an image processor52, a class identifier53, a spot determiner54, and a driving controller55. Note that these constituent elements51-55just represent respective functions to be performed by the processing unit5and none of these constituent elements51-55necessarily have a substantive configuration.

The image capturing controller51controls the image capturing unit41. Under the control of the image capturing controller51, the image capturing unit41shoots a work spot of the target article W1and thereby generates captured image data.

The image processor52performs image processing on the captured image data generated by the image capturing unit41. For example, the image processor52extracts, by using a convolutional neural network, a feature quantity from the captured image data generated by the image capturing unit41.

The class identifier53acquires identification information to identify the class of the target article W1shot by the image capturing unit41. As used herein, the expression “the class identifier53acquires the identification information” refers to both a situation where the class identifier53generates the identification information and a situation where the class identifier53acquires the identification information that has already been generated. That is to say, the class identifier53may generate the identification information or acquire the identification information that has been generated by a constituent element other than the class identifier53, whichever is appropriate.

In this embodiment, the communications unit12may communicate wirelessly with the wireless device D1, D2and the functions of the class identifier53include the function of acquiring the identification information from the wireless device D1or D2via the communications unit12.

Examples of the identification information include the model number, product number, and manufacturing lot number of the target article W1.

The spot determiner54determines the work spot that has been shot by the image capturing unit41. More specifically, the spot determiner54determines the work spot that has been shot by the image capturing unit41by comparing the captured image data generated by the image capturing unit41with reference image data belonging to a predetermined group. As used herein, the “predetermined group” refers to a group of reference image data items associated with the class of the target article W1identified by reference to the identification information.

That is to say, the spot determiner54obtains information about the class of the target article W1that has been shot by the image capturing unit41by referring, first, to the identification information that has been acquired by the class identifier53. In addition, the storage unit11also stores a plurality of reference image data items with the reference image data items classified into multiple groups according to the respective classes of the plurality of articles. The spot determiner54reads, from the storage unit11, two or more reference image data items belonging to the group corresponding to the class that has been identified by reference to the identification information. Then, the spot determiner54compares the two or more reference image data items thus read with the captured image data generated by the image capturing unit41.

The two or more reference image data items may represent, for example, the respective feature quantities of a plurality of work spots T1-T4(refer toFIG.3). The captured image data may represent, for example, the feature quantity of the work spot that has been shot by the image capturing unit41. The spot determiner54compares the two or more reference image data items with the captured image data, thereby determining whether or not the work spot shot by the image capturing unit41agrees with any one of the plurality of work spots T1-T4.

The driving controller55controls the driving unit31. The driving controller55may control the motor of the driving unit31, for example.

If the work spot determined by the spot determiner54conforms to the predetermined procedure, then the driving controller55allows the motor to turn. On the other hand, if the work spot does not conform to the predetermined procedure, then the driving controller55prohibits the motor from turning. For example, the wireless device D1or D2may instruct the tool system1to perform work on the work spots T1-T4of the target article W1in the order of T1, T2, T3, and T4. In that case, at a point in time before the work starts to be performed on the target article W1, the driving controller55allows the motor to turn only if the spot determiner54has determined that the work spot shot by the image capturing unit41be the work spot T1. Next, at a point in time after the work has been done on the work spot T1and before the work starts to be performed on the work spot T2, the driving controller55allows the motor to turn only if the spot determiner54has determined that the work spot shot by the image capturing unit41be the work spot T2.

Optionally, information about the working procedure with respect to the plurality of work spots may be stored in the storage unit11by, for example, making the image capturing unit41shoot the plurality of work spots T1-T4in an arbitrary order after the operation mode of the tool system1has been turned into an operation mode in which the working procedure is stored. Also, the reference image data may also be generated at this time.

Alternatively, information about the working procedure with respect to the plurality of work spots may be stored in advance in the storage unit11. Still alternatively, the information may also be transmitted from the wireless device D1or D2to the tool system1and stored in the storage unit11.

As shown inFIG.1, the high-order system6is an exemplary wireless device D1. The high-order system6may be installed in, for example, a factory where the target article W1is manufactured. The high-order system6communicates wirelessly with each of a plurality of tool systems1. The high-order system6manages the work being performed by the plurality of tool systems1.

The high-order system6includes a computer system including one or more processors and a memory. At least some of the functions of the high-order system6are performed by making the processor of the computer system execute a program stored in the memory of the computer system. The program may be stored in the memory. The program may also be downloaded via a telecommunications line such as the Internet or distributed after having been stored in a non-transitory storage medium such as a memory card.

The high-order system6includes a storage unit61, a communications unit62, and a processing unit63.

Examples of the storage unit61include a ROM, a RAM, and an EEPROM. The storage unit61stores, for example, the manufacturing schedule of a plurality of target articles W1.

The communications unit62includes a communications interface device. The communications unit62is ready to communicate with the tool system1via the communications interface device.

The processing unit63includes one or more processors of a computer system. The processing unit63performs overall control on the high-order system6.

As shown inFIG.1, the tag7is an exemplary wireless device D2. The tag7may be, for example, an RF ID tag. The tool system1communicates wirelessly with the tag7and reads out identification information stored in the tag7.

The tag7(wireless device D2) is an attachment of the target article W1. As used herein, the expression “the wireless device D2is an attachment of the target article W1” may refer to a situation where the wireless device D2is attached to the target article W1or a situation where the wireless device D2is built in the target article W1, whichever is appropriate. Alternatively, the expression “the wireless device D2is an attachment of the target article W1” may also refer to a situation where the wireless device D2and the target article W1are both provided on the same stage or in the same box, for example.

(10) Exemplary Use

Next, an exemplary use of the tool system1will be described with reference toFIG.4. Note that the flowchart shown inFIG.4shows just an exemplary method of using the tool system1according to the present disclosure. Thus, the processing steps shown inFIG.4may be performed in a different order as appropriate, an additional processing step may be performed as needed, or at least one of the processing steps may be omitted as appropriate. Note that in the following example, the target article W1shown inFIG.3is supposed to be a car component and the identification information is supposed to include car model information. The target article W1is supposed to have work spots T1-T4. Also, although the following description will be focused on a single tool system1, there may be a plurality of tool systems1. In that case, the processing to be described below will be performed by each of the plurality of tool systems1.

In an initial state, the driving controller55of the tool system1prohibits the working part32from performing any work. That is to say, in that state, the driving unit31is not activated.

(10.2) Identification of Target Article

The worker who uses the tool system1is present in a predetermined workplace in a factory. The tool system1acquires identification information from the wireless device D1or D2(if the answer is YES in Step ST1).

To provide the identification information from the wireless device D1(high-order system6) to the tool system1, the wireless device D1may receive, for example, from a carrier system for carrying the target article W1, identification information about the target article W1to be carried to the predetermined workplace. As a result, the identification information is transmitted to the tool system1.

On the other hand, to provide the identification information from the wireless device D2(tag7) as an attachment of the target article W1to the tool system1, the wireless device D2may start communicating with the tool system1as the target article W1is carried to the predetermined workplace, for example. As a result, the identification information stored in the wireless device D2is transmitted to the tool system1.

The storage unit11of the tool system1stores a plurality of reference image data items, each of which belongs to any one of multiple groups. The multiple groups are associated one to one with a plurality of classes. In this example, the plurality of classes are supposed to be respective car models.

On receiving the identification information, the tool system1determines whether the group associated with the class (car model) identified by this identification information is stored or not in the storage unit11(in Step ST2). Unless the associated group is stored in the storage unit11, the process goes back to Step ST1. On the other hand, if the associated group is stored in the storage unit11, the tool system1reads out two or more reference image data items belonging to that group (in Step ST3).

(10.3) Work on First Work Spot

Next, the worker performs a predetermined operation on the tool system1while pointing the image capturing unit41at the work spot such that the work spot falls within the image capturing range of the image capturing unit41. This allows the image capturing unit41to shoot the work spot and generate captured image data (in Step ST4). The work spot shot in this processing step may or may not be any one of the work spots T1-T4.

Next, the tool system1determines the work spot that has been shot (in Step ST5). That is to say, the tool system1compares the captured image data generated in Step ST4with the two or more reference image data items that have been read out in Step ST3and belong to a particular group (car model). Specifically, the tool system1compares a feature quantity represented by the captured image data with feature quantities represented by the two or more reference image data items. This allows the tool system1to determine whether or not the work spot that has been shot by the image capturing unit41is any one of the plurality of work spots T1-T4.

Next, the tool system1reads out working procedure information from the storage unit11. Then, the tool system1determines, by reference to the working procedure information read out from the storage unit11, whether or not the work spot determined in Step ST5is correct in working sequence (in Step ST6). For example, suppose that the work should be done on the work spots T1-T4of the target article W1in the order of T1, T2, T3, and T4. In that case, first, if the work spot determined in Step ST5is the work spot T1, then the tool system1answers “YES” to the query of Step ST6. Otherwise, the tool system1answers “NO” to the query of Step ST6. If the answer is NO in Step ST6, the process goes back to Step ST4.

If the answer is YES in Step ST6, then the process proceeds to Step ST7. In Step ST7, the driving controller55of the tool system1allows the working part32to perform work. That is to say, the driving controller55allows the motor of the driving unit31to turn. When the worker pulls the trigger switch221with the motor allowed to turn, the motor starts turning. This allows the working part32to perform a predetermined operation (i.e., to start turning) and thereby have the work done on the work spot T1. That is to say, a fastening member is attached to the work spot T1.

When the tool system1determines that the work have been done on the current work spot T1(if the answer is YES in Step ST8), then the process proceeds to Step ST9. The tool system1may determine, when finding the torque of the motor greater than a threshold value, for example, that the work have been done on the current work spot T1. Alternatively, the tool system1may also determine, when finding that the motor has kept turning for a predetermined time, for example, that the work have been done on the current work spot T1. Still alternatively, the tool system1may also determine, when finding that a predetermined time has passed since the motor started turning, for example, that the work have been done on the current work spot T1.

In Step ST9, the driving controller55of the tool system1prohibits the working part32from performing any work. That is to say, the driving controller55prohibits the motor from turning. Next, the tool system1determines whether or not the work has been done on the current target article W1(in Step ST10). That is to say, in Step ST10, the tool system1determines whether or not the work has been done on all of the work spots T1-T4. If the answer is YES in Step ST10, then the process goes back to Step ST1. In that case, when the next target article W1arrives, the same series of processing steps will be performed again following this flow on the next target article W1as the work target. On the other hand, if the answer is NO in Step ST10, the process goes back to Step ST4. Next, it will be described what processing steps are performed if the answer is YES in Step ST8(i.e., if the work has been done on the work spot T1) and then the process goes back to Step ST4.

(10.4) Work on Second Work Spot

The worker makes the image capturing unit41shoot the next work spot (in Step ST4). The tool system1determines the work spot that has been shot (in Step ST5). That is to say, the tool system1determines whether or not the work spot that has been shot by the image capturing unit41is any one of the plurality of work spots T1-T4.

Next, the tool system1determines, in Step ST6, by reference to the working procedure information read out from the storage unit11, whether or not the work spot determined in Step ST5is correct in working sequence. In this case, if the work spot determined in Step ST5is the work spot T2, then the tool system1answers “YES” to the query of Step ST6and allows the working part32to perform work (in Step ST7). Otherwise, the tool system1answers “NO” to the query of Step ST6.

If the tool system1determines that the work have been done on the work spot T2(if the answer is YES in Step ST8), then the driving controller55prohibits the working part32from performing work (in Step ST9). Then, the process goes back to Step ST4(if the answer is NO in Step ST10).

(10.5) Work on Third Work Spot

The worker makes the image capturing unit41shoot the next work spot (in Step ST4). The tool system1determines the work spot that has been shot (in Step ST5).

Next, the tool system1determines, in Step ST6, by reference to the working procedure information read out from the storage unit11, whether or not the work spot determined in Step ST5is correct in working sequence. In this case, if the work spot determined in Step ST5is the work spot T3, then the tool system1answers “YES” to the query of Step ST6and allows the working part32to perform work (in Step ST7). Otherwise, the tool system1answers “NO” to the query of Step ST6.

If the tool system1determines that the work have been done on the work spot T3(if the answer is YES in Step ST8), then the driving controller55prohibits the working part32from performing work (in Step ST9). Then, the process goes back to Step ST4(if the answer is NO in Step ST10).

(10.6) Work on Fourth Work Spot

The worker makes the image capturing unit41shoot the next work spot (in Step ST4). The tool system1determines the work spot that has been shot (in Step ST5).

Next, the tool system1determines, in Step ST6, by reference to the working procedure information read out from the storage unit11, whether or not the work spot determined in Step ST5is correct in working sequence. In this case, if the work spot determined in Step ST5is the work spot T4, then the tool system1answers “YES” to the query of Step ST6and allows the working part32to perform work (in Step ST7). Otherwise, the tool system1answers “NO” to the query of Step ST6.

If the tool system1determines that the work have been done on the work spot T4(if the answer is YES in Step ST8), then the driving controller55prohibits the working part32from performing work (in Step ST9).

By performing these processing steps, the tool system1has the work done on the work spots T1-T4. Thus, the answer to the query of Step ST10is YES and the process goes back to Step ST1. Thereafter, when the next target article W1arrives, the same series of processing steps will be performed again following this flow on the next target article W1as the work target.

The method of using the tool system1described above allows the tool system1to determine the work spot without using any reference image data items other than the items belonging to a particular group. For example, reference image data items corresponding to car models A, B, and C may be stored in the storage unit11. Suppose a situation where at a point in time, the target article W1on which the tool system1actually performs work corresponds to a car model A. In other words, suppose a situation where a target article W1corresponding to the car model A has been shot by the image capturing unit41. In that case, to determine the work spot, the tool system1refers to only the reference image data items corresponding to the car model A out of the reference image data items stored in the storage unit11and does not refer to the reference image data items corresponding to the car model B or C. This enables the tool system1to perform the processing of determining the work spot more speedily than in a situation where all of the reference image data items stored in the storage unit11are used. In addition, this may also reduce the chances of the tool system1taking, by mistake, the work spot shot by the image capturing unit41for a work spot corresponding to the car model B or C.

First Variation

Next, a tool system1according to a first variation will be described. In the following description, any constituent element of this first variation, having the same function as a counterpart of the embodiment described above, will be designated by the same reference numeral as that counterpart's, and description thereof will be omitted herein.

The tool system1according to this first variation has the function of generating the identification information. Thus, the tool system1according to the first variation does not have to receive the identification information by communicating wirelessly with the wireless device D1or D2. More specifically, the tool system1makes the image capturing unit41shoot the target article W1, thereby generating image data of the target article W1(as target image data). The tool system1has the function of generating the identification information by making an image analysis on the target image data. When using this function, the tool system1may perform the step of shooting the target article W1and the step of generating the identification information by making an image analysis on the target image data, instead of the step ST1(refer toFIG.4).

That is to say, in this first variation, the image capturing unit41generates target image data by shooting the target article W1. The functions of the class identifier53include the function of identifying the class of the target article W1based on the target image data and thereby generating the identification information.

To identify the class of the target article W1, the image capturing unit41may shoot a symbol attached to the target article W1so that the tool system1decodes the symbol. That is to say, the functions of the class identifier53may include the function of identifying the class of the target article W1by a symbol attached to the target article W1and thereby generating the identification information. In this case, the symbol attached to the target article W1may be, for example, a one-dimensional or two-dimensional barcode, a character, a numeral, a pattern, an icon, or a combination thereof. As used herein, the expression “symbol is attached to the target article W1” may refer to a situation where the symbol is inscribed, by printing, for example, directly on the target article W1or a situation where a tag, seal, or any other identifier with the symbol is attached to the target article W1, whichever is appropriate. Alternatively, the symbol may also be inscribed, by printing, for example, on a member (such as a stage or a box) on/in which the target article W1is supported or put. Still alternatively, a tag, seal, or any other identifier with the symbol may be attached to such a member.

Alternatively, to identify the class of the target article W1, the tool system1may determine the shape of at least a part of the target article W1by making an image analysis on the target image data. That is to say, the functions of the class identifier53may include the function of identifying the class of the target article W1by the shape of the target article W1and thereby generating the identification information.

Optionally, the image analysis of the target image data may also be made by an external device (such as the high-order system6or a cloud server) provided outside of the tool system1. That is to say, the tool system1may identify the class of the target article W1by acquiring the result of the image analysis from the external device.

Second Variation

Next, a tool system1according to a second variation will be described with reference toFIG.5. In the following description, any constituent element of this second variation, having the same function as a counterpart of the embodiment described above, will be designated by the same reference numeral as that counterpart's, and description thereof will be omitted herein.

In this second variation, the storage unit11stores a work schedule for a plurality of target articles W1. The tool system1identifies the class of the current target article W1by reference to the schedule.

This second variation will be described as being applied to a situation where the target articles W1are car components, target articles W1corresponding to car models A, B, A, and C, respectively, are carried in this order to a workplace in a factory, and the worker performs work on these target articles W1in the order of arrival.

First, the first target article W1is carried to the workplace. The storage unit11stores a schedule indicating that target articles W1corresponding to car models A, B, A, and C, respectively, are to be carried in this order. Thus, the tool system1determines the class of the first target article W1to be car model A. Also, when determining the work spot on the first target article W1, the tool system1refers to only the reference image data items corresponding to the car model A, without referring to reference image data items corresponding to the car model B or C, out of the reference image data items stored in the storage unit11.

When the work has been done on every work spot of the first target article W1, the second target article W1will be carried to the workplace. The tool system1determines, by reference to the schedule, the second target article W1to correspond to the car model B. Also, when determining the work spot on the second target article W1, the tool system1refers to only the reference image data items corresponding to the car model B, without referring to reference image data items corresponding to the car model A or C, out of the reference image data items stored in the storage unit11.

When the work has been done on every work spot of the second target article W1, the third target article W1will be carried to the workplace. The tool system1determines, by reference to the schedule, the third target article W1to correspond to the car model A. Also, when determining the work spot on the third target article W1, the tool system1refers to only the reference image data items corresponding to the car model A, without referring to reference image data items corresponding to the car model B or C, out of the reference image data items stored in the storage unit11.

When the work has been done on every work spot of the third target article W1, the fourth target article W1will be carried to the workplace. The tool system1determines, by reference to the schedule, the fourth target article W1to correspond to the car model C. Also, when determining the work spot on the fourth target article W1, the tool system1refers to only the reference image data items corresponding to the car model C, without referring to reference image data items corresponding to the car model A or B, out of the reference image data items stored in the storage unit11.

The tool system1may refer, to find the place in the work schedule of the target article W1, to either information about a time (e.g., point in time) when the target article W1was carried or information about the order in which the plurality of target articles W1are to be carried.

As can be seen, the storage unit11according to this second variation stores identification information associated with either time or order (as information to identify the car model, for example). The functions of the class identifier53include the function of acquiring the identification information from the storage unit11in accordance with the time or the order. This enables acquiring the identification information and identifying the class (such as the car model) of the target article W1even without acquiring the identification information from the wireless device D1or D2or making an image analysis of the target article W1.

Note that the schedule stored in the storage unit11may be updated every time the tool system1receives schedule update information from the wireless device D1or D2.

Optionally, the tool system1may further have the function of generating the identification information by making an image analysis of the target image data as in the first variation.

Additionally or alternatively, the tool system1may further have the function of receiving the identification information by wirelessly communicating with the wireless device D1or D2as in the exemplary embodiment described above.

(2) Exemplary Use

Next, an exemplary use of the tool system1according to this second variation will be described with reference toFIG.5. Note that the flowchart shown inFIG.5shows just an exemplary method of using the tool system1according to the second variation. Thus, the processing steps shown inFIG.5may be performed in a different order as appropriate, an additional processing step may be performed as needed, or at least one of the processing steps may be omitted as appropriate. Note that in the following example, the target article W1shown inFIG.3is supposed to be a car component and the identification information is supposed to include car model information. Also, although the following description will be focused on a single tool system1, there may be a plurality of tool systems1. In that case, the processing to be described below will be performed by each of the plurality of tool systems1.

In an initial state, the driving controller55of the tool system1prohibits the working part32from performing any work. That is to say, in that state, the driving unit31is not activated.

The worker who uses the tool system1is present in a predetermined workplace in a factory. The tool system1reads out a work schedule from the storage unit11(in Step ST21). This second variation will be described as being applied to a situation where a work schedule indicating that the worker is to perform work on target articles W1corresponding to car models A, B, A, and C in this order has been read out.

The tool system1specifies that the target article W1to be processed first by the tool system1be the first article on the schedule (in Step ST22). In this variation, the schedule has been arranged such that the work on a target article W1corresponding to the car model A will be performed first. Thus, the tool system1specifies that the target article W1to be processed first by the tool system1be a target article W1corresponding to the car model A.

The series of processing steps ST23-ST30that follow Step ST22are respectively the same as the processing steps ST3-ST10shown inFIG.4. Specifically, the tool system1determines the work spot by reference to the reference image data items corresponding to the car model A (in Step ST25) and allows the working part32to perform work on the target article W1when determining, by reference to the predetermined working procedure information, that the work spot thus determined is correct in working sequence (in Step ST27).

When the work has been done on all work spots (e.g., work spots T1-T4) of the first target article W1(if the answer is YES in Step ST30), the tool system1determines whether or not the schedule has been executed completely (in Step ST31). In other words, the tool system1determines whether or not the work has been done on four target articles W1corresponding to the car models A, B, A, and C in this order. In this case, the work has been done on only the first target article W1, and therefore, the tool system1updates the class of the target article W1(in Step ST32). That is to say, the tool system1updates the identification information about the class (car model) of the target article W1. After that, the tool system1determines the work spot by reference to the reference image data items belonging to the group associated with the car model B. In such a state, work is performed on the second target article W1.

When the work has been done on all work spots of the second target article W1(if the answer is YES in Step ST30), work will be performed in the same way on the third target article W1and the fourth target article W1. That is to say, when determining the work spot on the third target article W1, the tool system1refers to the reference image data items belonging to the group associated with the car model A. Next, when determining the work spot on the fourth target article W1, the tool system1refers to the reference image data items belonging to the group associated with the car model C.

When the work has been done on the first through fourth articles W1(if the answer is YES in Step ST31), the process will end.

Other Variations of Embodiment

Next, other variations of the exemplary embodiment will be enumerated one after another. Note that the variations to be described below may be adopted in combination as appropriate. Also, any of the variations to be described below may also be adopted as appropriate in combination with any of the first and second variations described above.

In the exemplary embodiment described above, the tool system1determines whether or not the work spot shot by the image capturing unit41agrees with any one of the plurality of work spots. Alternatively, the tool system1may also determine whether or not the work spot shot by the image capturing unit41is a particular work spot (such as the work spot T1). For example, if the work schedule is arranged such that work should be done first on the work spot T1with respect to a certain target article W1, then the tool system1may determine, before performing the work for the first time, whether or not the work spot shot by the image capturing unit41is the work spot T1.

The tool block3does not have to be an impact wrench. Alternatively, the tool block3may also be an electric screwdriver, drill, drill-screwdriver, saw, plane, nibbler, hole saw, or grinder, for example. Optionally, the tool block3may also be used for multiple purposes (e.g., as a screwdriver and as a drill) by changing the working part32.

The motive power supplied from the power source201to the driving unit31does not have to be electrical energy but may also be pneumatic pressure or hydraulic pressure, for example. That is to say, the tool block3does not have to be an electric tool.

The driving unit31may receive the motive power from an external power source provided outside of the tool system1. For example, the driving unit31may receive electrical energy from a commercial power supply or a private power generator as an alternative power source.

In the exemplary embodiment described above, the camera block4is provided for the tool block3. As used herein, if something is “provided for” something else, then the former may be built in (e.g., integrated inseparably with) the latter or may be just attached as an external member to the latter (e.g., removably secured with a coupler, for example). That is to say, the camera block4provided for the tool block3may be built in the tool block3or just attached as an external member to the tool block3, whichever is appropriate.

The camera block4does not have to be provided for the tool block3. Alternatively, the camera block4may also be provided for a housing which is provided separately from the tool block3. In that case, the camera block4may include, for example, a communications unit for communicating with the tool block3and may transmit the captured image data to the tool block3.

The wireless device D2does not have to be a tag. Alternatively, the wireless device D2may also be a radio beacon, for example. Still alternatively, a carrier for carrying the target article W1may be provided with a wireless communication capability and used as the wireless device D2.

The tool system1does not have to be used for assembling work at a factory but may also be used for any other purpose.

The tool system1does not have to either allow the driving unit31to be activated or prohibit the driving unit31from being activated depending on the work spot that has been determined. Alternatively, the operation mode of the tool system1may be changed, for example, according to the work spot determined. Still alternatively, a predetermined operation of the tool system1may or may not be restricted according to the work spot that has been determined.

The tool system1according to the present disclosure includes a computer system. The computer system may include, as principal hardware components, a processor and a memory. At least some of the functions of the tool system1according to the present disclosure may be performed by making the processor execute a program stored in the memory of the computer system. The program may be stored in advance in the memory of the computer system. Alternatively, the program may also be downloaded through a telecommunications line or be distributed after having been recorded in some non-transitory storage medium such as a memory card, an optical disc, or a hard disk drive, any of which is readable for the computer system. The processor of the computer system may be made up of a single or a plurality of electronic circuits including a semiconductor integrated circuit (IC) or a large-scale integrated circuit (LSI). As used herein, the “integrated circuit” such as an IC or an LSI is called by a different name depending on the degree of integration thereof. Examples of the integrated circuits include a system LSI, a very-large-scale integrated circuit (VLSI), and an ultra-large-scale integrated circuit (ULSI). Optionally, a field-programmable gate array (FPGA) to be programmed after an LSI has been fabricated or a reconfigurable logic device allowing the connections or circuit sections inside of an LSI to be reconfigured may also be adopted as the processor. Those electronic circuits may be either integrated together on a single chip or distributed on multiple chips, whichever is appropriate. Those multiple chips may be aggregated together in a single device or distributed in multiple devices without limitation. As used herein, the “computer system” includes a microcontroller including one or more processors and one or more memories. Thus, the microcontroller may also be implemented as a single or a plurality of electronic circuits including a semiconductor integrated circuit or a large-scale integrated circuit.

Also, in the embodiment described above, the functions of the tool system1are integrated together in a single housing. However, this is not an essential configuration for the tool system1. Alternatively, those constituent elements of the tool system1may be distributed in multiple different housings. Still alternatively, at least some functions of the tool system1, such as some functions of the processing unit5, may be implemented as a server or a cloud computing system as well.

Conversely, the plurality of functions that are distributed in multiple different housings in the embodiment described above may be integrated together in a single housing. For example, the tool system1may have some functions of the high-order system6.

The embodiment and its variations described above may be specific implementations of the following aspects of the present disclosure.

A tool system (1) according to a first aspect includes a driving unit (31), a working part (32), an image capturing unit (41), a storage unit (11), a class identifier (53), and a spot determiner (54). The driving unit (31) is activated with power supplied from a power source (201). The working part (32) is driven by the driving unit (31) to perform work on a work spot of a target article (W1). The image capturing unit (41) shoots the work spot and thereby generates captured image data. The storage unit (11) stores a plurality of reference image data items with the plurality of reference image data items classified into multiple groups according to respective classes of a plurality of articles. The plurality of reference image data items correspond to respective models of work spots of the plurality of articles. The class identifier (53) acquires identification information to identify the class of the target article (W1). The spot determiner (54) determines the work spot shot by the image capturing unit (41) by comparing the captured image data with one of the plurality of reference image data items, which belongs to one of the multiple groups that is associated with the class of the target article (W1) identified by reference to the identification information.

According to this configuration, the spot determiner (54) determines the work spot by using a reference image data item belonging to a group associated with the class of the target article (W1). That is to say, the spot determiner (54) may determine the work spot without using reference image data items not belonging to the target group. This enables speeding up the processing of determining the work spot, compared to using all reference image data items. In addition, this also reduces the chances of the spot determiner (54) taking a work spot, associated with a reference image data item not belonging to the target group, for a work spot on which work is going to be performed.

A tool system (1) according to a second aspect, which may be implemented in conjunction with the first aspect, further includes a communications unit (12) that communicates wirelessly with a wireless device (D1, D2). The class identifier (53) has at least the function of acquiring the identification information from the wireless device (D1, D2) via the communications unit (12). In other words, the class identifier (53) is configured to acquire the identification information from the wireless device (D1, D2) via the communications unit (12).

This configuration enables updating the identification information easily.

In a tool system (1) according to a third aspect, which may be implemented in conjunction with the second aspect, the wireless device (D2) is an attachment of the target article (W1).

This configuration enables updating the identification information via wireless communication by bringing the target article (W1) closer to the tool system (1), thus making it easier to manage the timing to update the identification information.

In a tool system (1) according to a fourth aspect, which may be implemented in conjunction with any one of the first to third aspects, the image capturing unit (41) shoots the target article (W1) and thereby generates target image data. The class identifier (53) has at least the function of identifying the class of the target article (W1) based on the target image data and thereby generating the identification information. In other words, the class identifier (53) is configured to identify the class of the target article (W1) based on the target image data and thereby generate the identification information.

This configuration enables acquiring the identification information even without using any wireless device (D1, D2).

In a tool system (1) according to a fifth aspect, which may be implemented in conjunction with the fourth aspect, the class identifier (53) has at least the function of identifying the class of the target article (W1) by a symbol attached to the target article (W1) and thereby generating the identification information. In other words, the class identifier (53) is configured to identify the class of the target article (W1) by a symbol attached to the target article (W1) and thereby generate the identification information.

This configuration enables acquiring the identification information by simple processing.

In a tool system (1) according to a sixth aspect, which may be implemented in conjunction with the fourth or fifth aspect, the class identifier (53) has at least the function of identifying the class of the target article (W1) by a shape of the target article (W1) and thereby generating the identification information. In other words, the class identifier (53) is configured to identify the class of the target article (W1) by a shape of the target article (W1) and thereby generate the identification information.

This configuration enables acquiring the identification information even if no symbol is attached to the target article (W1).

In a tool system (1) according to a seventh aspect, which may be implemented in conjunction with any one of the first to sixth aspects, the storage unit (11) stores the identification information associated with either time or order. The class identifier (53) has at least the function of acquiring the identification information from the storage unit (11) in accordance with either the time or the order. In other words, the class identifier (53) is configured to acquire the identification information from the storage unit (11) in accordance with either the time or the order.

This configuration enables acquiring the identification information earlier.

Note that the constituent elements according to the second to seventh aspects are not essential constituent elements for the tool system (1) but may be omitted as appropriate.