Patent Description:
Conventionally, a robot arm is known to which a tool is interchangeably attached to perform processing or operation on an object. For example, in the robot arm disclosed in Patent Document <NUM>, one of multiple types of tools is attached to the robot arm depending on processing to be performed on the object. The robot arm can grasp the object by opening and closing the tool.

In order to appropriately perform operations such as processing by the robot arm, tool conditions need to be satisfied, such as the tool attached being of the proper type and in the proper state (e.g., open state or closed state), depending on processing to be performed. In this regard, Patent Document <NUM> does not disclose a specific configuration for accurately determining whether the tool satisfies the tool conditions. <CIT> discloses analyzing a tool image for inspecting a selected tool upon execution of a tool change command. <CIT> discloses a matching recognition for machining steps and the corresponding cutter tools. <CIT> discloses identifying a tool among a plurality of different kinds of tools, based on a safe signal corresponding to the tool to be identified. <CIT> discloses identifying a hand attached to a robot device based on the corresponding identification number uniquely set for the hand.

An object of the present disclosure is to provide a workpiece processing system comprising a tool checking device, and a method for processing a workpiece with the workpiece processing system also comprising a robot arm whereby it is possible to accurately determine whether a tool satisfies a tool condition.

According to the present invention, there are provided a workpiece processing system comprising a tool checking device, and a method for processing a workpiece with the workpiece processing system as defined in the appended claims.

According to the present disclosure, there is provided a workpiece processing system comprising a tool checking device, and a method for processing a workpiece with the workpiece processing system also comprising a robot arm whereby it is possible to accurately determine whether a tool satisfies a tool condition.

Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It is intended, however, that unless particularly identified, dimensions, materials, shapes, relative positions, and the like of components described in the embodiments shall be interpreted as illustrative only and not intended to limit the scope of the present invention.

<FIG> is a diagram of a workpiece processing system <NUM> according to an embodiment. The workpiece processing system <NUM> according to an embodiment is provided to process a workpiece <NUM> using a tool <NUM>. The workpiece <NUM> is an object to be processed by the tool <NUM>. Examples of the workpiece <NUM> include food products such as agricultural products, livestock products, and marine products. The food product may be a fresh food product or processed food product. The following describes an embodiment in which the workpiece <NUM> is fresh meat.

The workpiece processing system <NUM> according to an embodiment includes a conveyance device <NUM> for conveying the workpiece <NUM>, a robot arm <NUM> for processing the workpiece <NUM>, an imaging device <NUM> for capturing an image of the tool <NUM>, an illumination unit <NUM> for illuminating an area captured by the imaging device <NUM>, and a tool checking device <NUM> for a robot arm.

The conveyance device <NUM> according to an embodiment is a belt conveyor for conveying the workpiece <NUM> in the horizontal direction.

The imaging device <NUM> according to an embodiment is provided to capture an image of the tool <NUM> from above. In this embodiment, the captured image <NUM> of the imaging device <NUM> is a planar image. <FIG> illustrates a captured image <NUM> of a clamper <NUM> (described later), which is an example of the tool <NUM>.

In an embodiment, the robot arm <NUM> is equipped with the tool <NUM>. In an embodiment, the tool checking device <NUM> checks whether the tool <NUM> is proper or not on the basis of the captured image <NUM>. Details of the configurations of the robot arm <NUM>, the tool <NUM>, and the tool checking device <NUM> will be described later.

In another embodiment, the conveyance device <NUM> may grasp and convey the workpiece <NUM> in a suspended position. The imaging device <NUM> may be configured to capture an image of the tool <NUM> along the horizontal direction, or may be configured to capture an image of the tool <NUM> along a direction inclined with respect to the horizontal direction. Further, the workpiece processing system <NUM> may not include the illumination unit <NUM>. In this case, the function of the illumination unit <NUM> may be included in the imaging device <NUM>.

The configuration of the robot arm <NUM> will be described. The robot arm <NUM> according to an embodiment is an industrial robot. More specifically, for example, the robot arm <NUM> is an articulated robot. The robot arm <NUM> may be a vertical articulated robot, a horizontal articulated robot, or a combination thereof.

The robot arm <NUM> according to an embodiment includes robot arms 30a, 30b, 30c. In an embodiment, the tool <NUM> attached to the robot arm <NUM> is made of a metallic material. Further, the tool <NUM> according to an embodiment has a surface that reflects light more easily than the workpiece <NUM>, for example.

The tool <NUM> according to an embodiment includes a clamper <NUM> for gripping the workpiece <NUM>, a chuck <NUM> for chucking the workpiece <NUM>, and a knife <NUM> for cutting the workpiece <NUM>.

In an embodiment, the clamper <NUM> is attached to the robot arm 30a, and the chuck <NUM> and the knife <NUM> are attached to the robot arm 30b or the robot arm 30c.

In an embodiment, left-right symmetrical tools <NUM> are prepared to be used according to the type of workpiece <NUM>. As a specific example, the chuck <NUM> includes chucks <NUM> and 42R, the knife <NUM> includes knives <NUM> and 43R, and these tools <NUM> are selectively attached to the robot arms 30b and 30c. For example, when the workpiece <NUM> conveyed by the conveyance device <NUM> is either a left limb or a right limb of livestock, the chuck <NUM> and the knife 43R are attached to the robot arms 30b and 30c, respectively. When the workpiece <NUM> is the other, the knife <NUM> and the chuck 42R are attached to the robot arms 30b and 30c, respectively. In an embodiment, the attachment work is performed by an operator. In another embodiment, the attachment work may be performed by separate robots.

The clamper <NUM> and the chuck <NUM> according to an embodiment obtain driving force from a driving source to perform opening and closing operations. In an embodiment, an air cylinder (not shown) is used as the driving source. In this case, the inlet and outlet provided in each of the clamper <NUM> and the chuck <NUM> are connected to the air cylinder via air pipes. A hydraulic cylinder or a motor may be used as the driving source.

In another embodiment, the workpiece processing system <NUM> may not include the left-right symmetrical tools <NUM>. For example, the chuck <NUM> may include only one of chucks <NUM> and 42R. Similarly, the knife <NUM> may include only one of knives <NUM>, 43R. In still another embodiment, each of the robot arms <NUM> may be equipped with only one tool <NUM>.

Further, the workpiece processing system <NUM> is not limited to having a plurality of robot arms <NUM>. A single robot arm <NUM> may be selectively equipped with multiple types of tools <NUM> or only one tool <NUM>.

The configuration of the tool checking device <NUM> for a robot arm (hereinafter also referred to as "tool checking device <NUM>") will be described. The tool checking device <NUM> uses a tool condition regarding the tool type or tool state that needs to be satisfied by the tool <NUM> as a criterion for checking. In an embodiment, the tool check is performed based on an evaluation value regarding the captured image <NUM>. The evaluation value according to an embodiment is a brightness value regarding the captured image <NUM> as described later.

The tool type is the type of the tool <NUM> that should be attached to the robot arm <NUM>. The tool type according to an embodiment is the clamper <NUM>, the chuck <NUM>, or the knife <NUM>. For example, if the knife <NUM> is attached to the robot arm 30b even though the chuck <NUM> should be attached, the tool condition regarding the tool type is not satisfied. Such cases can occur, for example, if the operator inadequately replaces the tool <NUM>.

The tool state is the state that should be met by the tool <NUM> attached to the robot arm <NUM>. The tool state according to an embodiment includes the open state or closed state of the clamper <NUM> and the chuck <NUM>, and the normal state of the knife <NUM>. For example, if the tool <NUM> such as the clamper <NUM> or the chuck <NUM> should be in the closed state but is in the open state, the tool condition regarding the tool state is not satisfied. Such cases can occur, for example, if connection between the clamper <NUM> or the chuck <NUM> and the air cylinder through the air pipe is inadequate. On the other hand, if the knife <NUM> is missing even though it should be in the normal state, the tool condition regarding the tool state is not satisfied. Such cases can occur, for example, due to the continuous use of the knife <NUM>.

In an embodiment, the tool types and tool states are managed in associated with each other. Thus, the tool checking device <NUM> can check whether the type and state are both proper in a single check. As a specific example, the tool checking device <NUM> may determine in a single check whether the tool condition corresponding to the clamper <NUM> as the tool type and the open state as the tool state is satisfied. Alternatively, it may determine in a single check whether the tool condition corresponding to the knife <NUM> as the tool type and the normal state as the tool state is satisfied.

In another embodiment, the tool types and tool states do not have to be associated with each other. For example, the tool checking device <NUM> may separately determine whether the tool condition regarding the tool type and the tool condition regarding the tool state are satisfied.

In another embodiment, the tool condition may be a condition related only to the tool type. In other words, only whether the type of the tool <NUM> attached to the robot arm <NUM> is proper may be determined. Alternatively, the tool condition may be a condition related only to the tool state. For example, in an embodiment where the robot arm <NUM> is equipped with only one tool <NUM>, only whether the state of the tool <NUM> is proper is determined.

The configuration of the tool checking device <NUM> will be described. The tool checking device <NUM> according to an embodiment includes a condition acquisition unit <NUM>, a tool movement control unit <NUM>, an imaging control unit <NUM>, an image processing unit <NUM>, a brightness value acquisition unit <NUM>, and a determination unit <NUM>. The functions of these components are implemented by a processor <NUM> (see <FIG>) as will be described later.

The condition acquisition unit <NUM> according to an embodiment is configured to acquire a tool condition according to a work schedule (operation schedule) of the robot arm <NUM> after the tool condition is determined to be satisfied. For example, if work with the clamper <NUM> in the open state is scheduled as the work after the tool condition is determined to be satisfied, the condition acquisition unit <NUM> acquires the tool condition where the tool type is the clamper <NUM> and the tool state is the open state.

In an embodiment, a plurality of works may be scheduled for each of a plurality of robot arms <NUM>. In this case, the condition acquisition unit <NUM> may acquire tool conditions according to the plurality of robot arms <NUM>.

The tool movement control unit <NUM> according to an embodiment is provided to control the robot arm <NUM> so as to move the tool <NUM> attached to the robot arm <NUM> to a defined position P2 (see <FIG>). As a more specific example, the tool movement control unit <NUM> is provided to control the robot arm <NUM> so as to move the tool <NUM> from an inner position P1 (see <FIG>) within an imaging range of the imaging device <NUM> to a defined position P2 where a difference in the evaluation value according to whether the tool condition is satisfied is greater than in the inner position P1.

Further, the tool movement control unit <NUM> according to an embodiment is configured to selectively control the robot arm <NUM> to be controlled among a plurality of the robot arms <NUM>. In an embodiment, the robot arm <NUM> to be controlled is specified on the basis of the tool condition acquired by the condition acquisition unit <NUM>.

The imaging control unit <NUM> according to an embodiment is provided to control the imaging device <NUM> so as to capture an image of the tool <NUM> moved to the defined position P2.

The image processing unit <NUM> according to an embodiment is configured to perform, on the captured image <NUM>, image processing associated with the tool condition, and generate a processed image <NUM> (see <FIG> and <FIG>) in which a related area <NUM> associated with the tool condition is extracted. The processed image <NUM> generated is an image based on the captured image <NUM>. The processed image <NUM> may be generated by subjecting the entire captured image <NUM> to image processing, or may be generated by subjecting a partial image of the captured image <NUM> to image processing.

The related area <NUM> according to an embodiment is an area set such that there is a difference in the image between when the tool condition is satisfied and when it is not satisfied. The processed image <NUM> obtained by extracting this related area <NUM> is used to determine by the determination unit <NUM> whether the tool condition is satisfied.

An example of the related area <NUM> associated with the tool condition will be described. For example, the related area <NUM> associated with the tool condition regarding the tool state of the clamper <NUM> is set to be an area where at least a part of the movable portion of the clamper <NUM> enters or exits depending on the state of the clamper <NUM> (open or closed state). The related area <NUM> may be set at the time of determination by the determination unit <NUM> or may be set in advance before the determination.

The related area <NUM> according to an embodiment is an area along at least a part of the contour of the tool <NUM> that satisfies the tool condition and is an area to be trimmed.

In an embodiment, the processed image <NUM> in which the related area <NUM> is extracted is an image generated by masking. In this embodiment, the image processing unit <NUM> is configured to perform masking using a reference image <NUM> (see <FIG>) associated with the tool condition, and generate a processed image <NUM> in which the related area <NUM> associated with the tool condition is extracted. The reference image <NUM> associated with the tool condition will be described later.

The brightness value acquisition unit <NUM> according to an embodiment is configured to acquire a brightness value of an area included in the captured image <NUM> as the evaluation value based on the captured image <NUM>. The area included in the captured image <NUM> may be, for example, the entire area of the processed image <NUM>. The brightness value acquisition unit <NUM> may acquire only a brightness value in the related area <NUM> as the area included in the captured image <NUM>.

In an embodiment, the brightness value acquisition unit <NUM> acquires an RGB brightness value of the area included in the captured image <NUM>.

The determination unit <NUM> according to an embodiment is configured to determine whether the tool <NUM> satisfies the tool condition regarding the tool type or tool state that needs to be satisfied, on the basis of the captured image <NUM> imaged by the imaging device <NUM>. As a more specific example, the determination unit <NUM> is configured to determine whether the tool condition is satisfied, on the basis of the captured image <NUM> of the tool <NUM> attached to the robot arm <NUM> to be controlled by the tool movement control unit <NUM>. In an embodiment where a plurality of robot arms <NUM> are controlled, the determination unit <NUM> may sequentially determine whether the tool condition is satisfied for the tools <NUM> attached to these robot arms <NUM>.

The determination unit <NUM> according to an embodiment is configured to determine whether the tool condition is satisfied on the basis of the evaluation value regarding the captured image <NUM>. The evaluation value may be, for example, a brightness value of the processed image <NUM>, or more specifically, may be the sum of brightness values of the processed image <NUM>. The evaluation value may be a brightness value of the captured image <NUM> that has not been processed.

In another embodiment, the condition acquisition unit <NUM> may not be provided. For example, if the tool condition is uniquely defined, then the image processing unit <NUM> may perform image processing associated with this tool condition to generate a processed image <NUM>, and the determination unit <NUM> may determine whether this tool condition is satisfied on the basis of the processed image <NUM>.

<FIG> is a diagram showing the flow of moving the tool <NUM> to the defined position P2 according to an embodiment. <FIG> illustrates the clamper <NUM> as an example of the tool <NUM> as viewed along the conveying direction of the conveyance device <NUM>.

The clamper <NUM> according to an embodiment is moved from a movement start position P0 via an inner position P1 to the defined position P2 by controlling the robot arm 30a with the tool movement control unit <NUM>. The movement start position P0 may be a position outside the imaging range of the imaging device <NUM> or a position within the imaging range. The inner position P1 and the defined position P2 are different positions from each other within the imaging range.

In an embodiment, the movement start position P0, the inner position P1, and the defined position P2 are concepts including a three-dimensional coordinate position and a rotational position (rotational posture) with the horizontal direction as the axial direction. Therefore, in the process of moving the clamper <NUM> from the inner position P1 to the defined position P2, the position of the clamper <NUM> in the three-dimensional coordinate system and the rotational position (rotational posture) of the clamper <NUM> with the horizontal direction as the axial direction are adjusted.

In an embodiment, the defined position P2 is a position where the difference in the evaluation value regarding the captured image <NUM> between when the tool condition is satisfied and it is not satisfied is greater than in the inner position P1. As a more specific example, the clamper <NUM> in the defined position P2 reflects more light toward the imaging device <NUM> than in the inner position P1. Therefore, when the clamper <NUM> is in the defined position P2, the brightness value of the captured image <NUM> when the tool condition is satisfied increases. On the other hand, the brightness value of the captured image <NUM> when the tool condition is not satisfied does not change significantly regardless of whether the clamper <NUM> is in the defined position P2 or the inner position P1. As a result, the difference in the evaluation value regarding the captured image <NUM> between when the tool condition is satisfied and when it is not satisfied is larger in the defined position P2 than in the inner position P1.

The evaluation value regarding the captured image <NUM> in the inner position P1 may be obtained experimentally (e.g., by experiment or simulation) in advance before the determination by the determination unit <NUM>.

In the above, the process of moving the clamper <NUM> to the defined position P2 has been described, but the other tools <NUM> (e.g., chuck <NUM> or knife <NUM>) can also be moved in the same way by controlling the robot arms 30b and 30c with the tool movement control unit <NUM>. Detailed description will be omitted.

In another embodiment, the movement start position P0 may coincide with the inner position P1. In other words, the tool movement control unit <NUM> may start moving the tool <NUM> from the inner position P1.

In another embodiment, the rotational position (rotational posture) with the vertical direction as the axial direction may be adjusted in the process of moving the tool <NUM> to the defined position P2.

<FIG> is a diagram showing the defined position P2 of the tool <NUM> according to an embodiment.

In <FIG>, for convenience, the center of gravity of the portion of the tool <NUM> connected to the robot arm <NUM> is illustrated as the defined position P2, but as described above, the defined position P2 may include the rotational position (rotational posture) of the tool <NUM> with the horizontal or vertical direction as the axial direction.

In an embodiment, different defined positions P2 are set depending on the tool type to be satisfied. For example, the clamper <NUM>, the chucks <NUM>, 42R, and the knife <NUM>, 43R may have defined positions P2 that are different from each other in the conveying direction. These defined positions P2 may be at the same height.

In an embodiment, when the tool type to be satisfied is the same, the same defined position P2 is set regardless of the tool state to be satisfied. For example, when the tool type to be satisfied is the clamper <NUM>, the same defined position P2 is set regardless of the tool state (open or closed state) to be satisfied.

In an embodiment, the imaging device <NUM> has a wide imaging range such that any defined position P2 can be captured. In this case, a partial image extracted according to the defined position P2 from the image generated by the imaging device <NUM> is used as the captured image <NUM>. The image processing to extract the partial image may be, for example, trimming or cropping.

In another embodiment, the imaging range of the captured image <NUM> may be so narrow that it can only include either defined position P2. In this case, the optical axis direction of the imaging device <NUM> may be adjusted according to the defined position P2, and the image generated by the imaging device <NUM> may be treated as the captured image <NUM> as it is.

<FIG> is a diagram showing reference image data <NUM> which is data of a reference image <NUM> for executing image processing according to an embodiment.

The reference image <NUM> according to an embodiment is associated with the tool condition.

The image processing unit <NUM> according to an embodiment applies masking to the captured image <NUM> using the reference image <NUM> associated with the tool condition. As a result, an image in which the related area <NUM> associated with the tool condition is extracted is generated as the processed image <NUM> (see <FIG> and <FIG>).

In an embodiment, as an example, a total of eight types of reference images 14a to <NUM> are prepared corresponding to tool conditions.

<FIG> and <FIG> are each a diagram for describing a determination method by the determination unit 59a, 59b (<NUM>) according to an embodiment.

In the determination shown in <FIG> and <FIG>, the tool condition that needs to be satisfied is the clamper <NUM> in the open state. "Check A" in the figures shows the checking process of the clamper <NUM> in the open state, which satisfies the above tool condition. "Check B" in the figures shows the checking process of the clamper <NUM> in the closed state, which does not satisfy the above tool condition.

In an embodiment, in both checks A and B, the workpiece <NUM> is arranged below the tool <NUM> when imaged by the imaging device <NUM> (in <FIG> and <FIG>, the workpiece <NUM> is hatched for ease of reading the figures). However, the workpiece <NUM> may not be visible in the background of the tool <NUM> when imaging by the imaging device <NUM>.

In an embodiment, during checks A and B, the image processing unit <NUM> applies masking to the respective captured images <NUM> using the reference image <NUM> associated with the tool condition to generate the respective processed images <NUM>. Then, the brightness value acquisition unit 56a, 56b (<NUM>) acquires brightness values of the processed images <NUM>.

The brightness value acquisition unit 56a shown in <FIG> is configured to acquire the sum X<NUM> of brightness values of the processed image 18a.

For example, when the number of pixels in the x-direction (horizontal direction) of the processed image <NUM> is M, the number of pixels in the y-direction (vertical direction) is N, and the brightness value at any pixel is B, the sum X<NUM> of brightness values acquired by the brightness value acquisition unit 56a is defined by the equation (<NUM>). Here, i is any natural number equal to or less than the number of pixels in the horizontal direction of the processed image <NUM>, and j is any natural number equal to or less than the number of pixels in the vertical direction. (Expression <NUM>) <MAT>.

In another embodiment, X<NUM> may be the sum of brightness values of the related area <NUM> in the processed image <NUM>.

The determination unit 59a according to an embodiment is configured to determine whether the tool condition is satisfied on the basis of the sum X<NUM> of brightness values acquired.

In an embodiment, the determination unit 59a determines whether the tool condition is satisfied in checks A and B on the basis of the sum X<NUM> of brightness values acquired by the brightness value acquisition unit 56a in each of checks A and B. For example, in check A, the clamper <NUM> appears over almost the entire related area <NUM> of the processed image <NUM>, and objects (e.g., workpiece <NUM>) other than the clamper <NUM> hardly appear in the related area <NUM>. In this case, the sum X<NUM> of brightness values of the processed image <NUM> acquired by the brightness value acquisition unit 56a exceeds a threshold T<NUM>, which is the criterion, and the determination unit 59a determines that the tool condition is satisfied.

In contrast, in check B, the proportion occupied by the clamper <NUM> in the related area <NUM> of the processed image <NUM> is smaller (the movable portion of the clamper <NUM> is mostly out of the related area <NUM>). As a result, the proportion of other objects (e.g., workpiece <NUM>) in the related area <NUM> increases. Accordingly, the sum X<NUM> of brightness values of the processed image <NUM> falls below the threshold T<NUM>, and the determination unit 59a determines that the tool condition is not satisfied.

The brightness value acquisition unit 56b shown in <FIG> is configured to acquire the sum X<NUM> of differences between brightness values identified by the following equation (<NUM>) using Bij which is a brightness value of each pixel of the processed image <NUM>, and Bsij which is a brightness value set for each pixel according to the tool condition. (Expression <NUM>) <MAT>.

The brightness value acquisition unit 56b according to an embodiment acquires the sum X<NUM> of differences between the brightness value Bij of each pixel of the processed image <NUM> and the brightness value Bsij of each pixel of a normal image <NUM> corresponding to each pixel of the processed image <NUM> in each of checks A and B.

In an embodiment, as advance preparation, the image processing unit <NUM> applies masking to the captured image <NUM> of the tool <NUM> that is determined to satisfy the tool condition. As a result, a normal image <NUM>, which is a processed image obtained by extracting the related area <NUM> associated with the tool condition, is generated in advance. By acquiring the normal image <NUM>, the brightness value acquisition unit 56b acquires the brightness value Bsij.

In another embodiment, the image processing unit <NUM> may not generate the normal image <NUM>. For example, the brightness value Bsij set for each pixel of the processed image <NUM> may be stored in some memory in advance.

In another embodiment, Bsij may be the brightness value for each pixel in the related area <NUM> only, instead of the brightness value for each pixel in the processed image <NUM>. In this case, Bsij also represents the brightness value of each pixel corresponding to the related area <NUM> only.

The determination unit 59b according to an embodiment determines whether the tool condition is satisfied on the basis of the sum X<NUM> of differences between brightness values acquired.

The determination unit 59b according to an embodiment determines whether the tool condition is satisfied in checks A and B on the basis of the sum X<NUM> of differences between brightness values acquired by the brightness value acquisition unit 56b in each check. For example, in check A, since the difference between the processed image <NUM> and the normal image <NUM> is small, the sum X<NUM> of differences between brightness values falls below a threshold T<NUM>, which is the criterion, and the determination unit 59b determines that the tool condition is satisfied.

In contrast, in check B, since the difference between the processed image <NUM> and the normal image <NUM> is large, the sum X<NUM> of differences between brightness values is not less than the threshold T<NUM>. Thus, the determination unit 59b determines that the tool condition is not satisfied.

<FIG> and <FIG> show the example where the tool <NUM> that does not satisfy the tool condition is the clamper <NUM> in the closed state, but the same determination result can be obtained with the same determination method even if another tool <NUM> that does not satisfy the tool condition is judged.

Further, in <FIG> and <FIG>, the clamper <NUM> in the open state is shown as an example of the tool condition that needs to be satisfied, but the same determination result can be obtained with the same determination method even if the target to be judged is another tool condition.

<FIG> is a block diagram showing an electrical configuration of the workpiece processing system <NUM> according to an embodiment. The components of the aforementioned tool checking device <NUM> are implemented by a processing control unit <NUM> shown in <FIG>. A specific implementation method will be described below with reference to <FIG>.

The workpiece processing system <NUM> is provided with a processing control unit <NUM> including a processor <NUM>.

The processor <NUM> reads out a processing control program (tool checking program) <NUM> stored in ROM <NUM> and loads it into RAM <NUM> to execute instructions included in the loaded processing control program <NUM>. The processor <NUM> is CPU, GPU, MPU, DSP, other various kinds of computation devices, or a combination thereof. The processor <NUM> may be implemented by an integrated circuit of PLD, ASIC, FPGA, MCU, etc. The ROM <NUM> is an example of the storage device.

A memory <NUM>, which is a component of the processing control unit <NUM>, is a non-volatile memory which stores reference image data <NUM> and defined position data <NUM> indicating the defined position P2. The defined position data <NUM> according to an embodiment may be a data table also including identification data indicating the robot arm <NUM> to be controlled. For example, the defined position data <NUM> may associate the data indicating the defined position P2 of the clamper <NUM> with the identification data of the robot arm 30a to which the clamper <NUM> is attached.

The processor <NUM> according to an embodiment is connected to an acceptance button <NUM>, the conveyance device <NUM>, the robot arm <NUM>, the imaging device <NUM>, and the alarm device <NUM> via an interface (not shown).

The acceptance button <NUM> according to an embodiment accepts a tool condition that needs to be satisfied by the tool <NUM>. The acceptance button <NUM> may be a button with a mechanical structure or a touch panel button.

In an embodiment, the operator may input the tool condition to the acceptance button <NUM> when attaching the tool <NUM> to the robot arm <NUM>. The input tool condition may be, for example, a plurality of conditions corresponding to the number of robot arms <NUM>. The acceptance button <NUM> outputs the accepted tool condition to the processor <NUM>. When the operator inputs the tool condition to the acceptance button <NUM>, the operator may also input the robot arm <NUM> corresponding to the tool condition.

The processor <NUM> acquires the tool condition by acquiring data output from the acceptance button <NUM>.

In another embodiment, the acceptance button <NUM> may not be provided. In this case, the processor <NUM> may acquire the tool condition indicated by data included in the processing control program <NUM>, for example.

The conveyance device <NUM>, the robot arm <NUM>, the imaging device <NUM>, and the alarm device <NUM> according to an embodiment operate in response to control signals received from the processor <NUM>. The robot arm <NUM> according to an embodiment moves the tool <NUM> to a defined position P2 in response to a control signal received. In an embodiment, the robot arm <NUM> further performs processing on the workpiece <NUM> in response to a control signal received.

The imaging device <NUM> according to an embodiment captures an image in response to a control signal received and outputs the generated captured image <NUM> to the processor <NUM>. The processor <NUM> according to an embodiment outputs the image acquired from the imaging device <NUM> to the RAM <NUM>. The captured image <NUM> may be stored in the memory <NUM> instead of the RAM <NUM>.

The alarm device <NUM> according to an embodiment is a device for issuing an alarm in response to a control signal received when the processor <NUM> determines that the tool condition is not satisfied. The alarm device <NUM> according to an embodiment may be an image display device, a speaker, a light emitting device, or a combination thereof.

<FIG> is a flowchart of a processing control process according to an embodiment. In the processing control process, the processor <NUM> loads the processing control program <NUM> stored in the ROM <NUM> into the RAM <NUM> to execute the following steps. Information processed by the processor <NUM> in executing the process is stored in the RAM <NUM> or the memory <NUM>, as appropriate. In the following description, "step" is abbreviated as "S".

The processor <NUM> controls the conveyance device <NUM> so that the workpiece <NUM> is conveyed to the processing area (S11).

Then, the processor <NUM> acquires a tool condition that needs to be satisfied by the tool <NUM> (S13). For example, the processor <NUM> acquires a tool condition on the basis of data output from the acceptance button <NUM>. The processor <NUM> executing S11 functions as the condition acquisition unit <NUM>. In an embodiment where a plurality of robot arms <NUM> are provided, the processor <NUM> may acquire a tool condition corresponding to each robot arm <NUM>.

The processor <NUM> refers to the tool condition acquired in S13 and the defined position data <NUM> stored in the memory <NUM> and selectively controls the robot arm <NUM> to be controlled (S15). Thus, the tool <NUM> attached to the robot arm <NUM> to be controlled is moved to the defined position P2. For example, if the tool condition acquired in S11 includes "clamper <NUM> in the open state", the processor <NUM> performs control so that the clamper <NUM> attached to robot arm 30a moves to the defined position P2, and the chuck <NUM> and the knife <NUM> attached to the robot arms 30b and 30c retreat to other positions (e.g., movement start position P0). The processor <NUM> executing S15 functions as the tool movement control unit <NUM>.

The processor <NUM> controls the imaging device <NUM> so as to capture an image of the tool <NUM> moved to the defined position P2 by execution of S15 (S17). The processor <NUM> stores the captured image <NUM> based on imaging by the imaging device <NUM> into the RAM <NUM>, for example. The processor <NUM> executing S17 functions as the imaging control unit <NUM>.

The processor <NUM> processes the captured image <NUM> generated in S17 (S19). In an embodiment, the processor <NUM> refers to the reference image data <NUM> stored in the memory <NUM> and acquires the reference image <NUM> according to the tool condition acquired in S13. Then, using the acquired reference image <NUM>, masking is applied to the captured image <NUM> acquired in S17. As a result, the processor <NUM> generates an image in which the related area <NUM> associated with the tool condition is extracted as a processed image <NUM>. The processor <NUM> executing S19 functions as the image processing unit <NUM>.

The processor <NUM> acquires brightness values of the processed image <NUM> on the basis of the processed image <NUM> generated (S21). In an embodiment, the processor <NUM> acquires the sum X<NUM> of brightness values or the sum X<NUM> of differences between brightness values, for example, on the basis of the equation (<NUM>) or equation (<NUM>).

When acquiring the sum X<NUM> of differences between brightness values, the processor <NUM> may refer to the normal image <NUM> stored in the memory <NUM> to acquire the brightness value Bsij of each pixel.

The processor <NUM> executing S21 functions as the brightness value acquisition unit 56a, 56b (<NUM>).

On the basis of the acquired brightness values, the processor <NUM> determines whether the tool condition acquired in S13 is satisfied (S23).

For example, the processor <NUM> determines whether the tool condition is satisfied by comparing the sum X<NUM> of brightness values or the sum X<NUM> of differences between brightness values with the threshold T<NUM> or the threshold T<NUM>. The processor <NUM> executing S23 functions as the determination unit 59a, 59b (<NUM>).

If it is determined that the tool condition is not satisfied (S23: NO), the processor <NUM> controls the alarm device <NUM> to issue an alarm (S25), and ends this control process.

In an embodiment, when the alarm is issued, the operator recognizes that the tool condition is not satisfied, and can replace the tool <NUM> or perform other operations on the robot arm <NUM> to satisfy the tool condition.

In an embodiment, if it is determined that the tool condition is satisfied (S23: YES), the processor <NUM> determines whether the tool check is completed (S27). For example, when there remains a tool condition that has not been determined to be satisfied or not among multiple tool conditions acquired in S13 (S27: NO), the processor <NUM> repeats S15 to S23. On the other hand, if the determination of all tool conditions is completed (S27: YES), the processor <NUM> proceeds to S29.

The processor <NUM> controls the robot arm <NUM> so that the tool <NUM> in the defined position P2 retreats to a different position (e.g., movement start position P0) (S29). The processor <NUM> then controls the imaging device <NUM> to capture an image of the workpiece <NUM> (S31) and analyzes the image generated by the imaging device <NUM> (S33). In an embodiment, the processor <NUM> performs image analysis for suitable processing on the imaged workpiece <NUM>. As a specific example, if the workpiece <NUM> is a boned limb of livestock, image analysis is performed to identify the position of the bone in the workpiece <NUM>. The analysis may be performed, for example, by inputting the image taken in S31 to a previously machine-learned trained model. In this case, the processor <NUM> may be equipped with a GPU for performing arithmetic processing based on the machine-learned trained model. The processor <NUM> controls the robot arm <NUM> so that the workpiece <NUM> is processed on the basis of the result of image analysis (S35). After the processing of the workpiece <NUM> is completed, the processor <NUM> ends this control process.

In another embodiment, the execution timing of S11 may be after it is determined that the tool check is completed (S27: YES). In this case, the workpiece <NUM> does not appear in the captured image <NUM> in the imaging of S17.

In another embodiment, for example, when the tool condition to be judged is uniquely defined, neither S13 nor S27 may be executed. The uniquely defined tool condition means not only a single tool condition but also multiple tool conditions.

Hereinafter, the tool checking device <NUM> for a robot arm, the tool checking program <NUM> for a robot arm, and the tool checking method for a robot arm according to some aspects of the present disclosure will be described.

With the above configuration (<NUM>), since the tool <NUM> is moved to the defined position P2 in accordance with the control by the tool movement control unit <NUM>, the evaluation value regarding the captured image <NUM> changes significantly according to whether the tool condition is satisfied. Therefore, it is possible to accurately determine whether the tool condition is satisfied.

For example, the brightness value of the related area <NUM> when the tool condition is satisfied is larger when the clamper <NUM> is in the defined position P2 than in the inner position P1. On the other hand, when the tool condition is not satisfied, objects other than the tool <NUM>, such as the workpiece <NUM>, appear in the related area <NUM> regardless of whether the clamper <NUM> is in the inner position P1 or the defined position P2, and the brightness value of the related area <NUM> does not change significantly in both positions. As a result, the difference in the brightness value according to whether the tool condition is satisfied increases when the clamper <NUM> is in the defined position P2. Thus, the determination unit 59b can accurately determine whether the tool condition is satisfied.

(<NUM>) According to some aspects of the present disclosure, in the above configuration (<NUM>) or (<NUM>), the tool checking device <NUM> further includes a brightness value acquisition unit <NUM> configured to acquire a brightness value of an area (related area <NUM>) included in the captured image <NUM>. The determination unit <NUM> is configured to determine whether the tool condition is satisfied on the basis of the brightness value acquired.

With the above configuration (<NUM>), the determination unit <NUM> can perform quantitative determination as to whether the tool condition is satisfied on the basis of the brightness value of the area included in the captured image <NUM>. Thus, it is possible to accurately determine whether the tool <NUM> satisfies the tool condition.

(<NUM>) According to some aspects of the present disclosure, in the above configuration (<NUM>), the brightness value acquisition unit 56a (<NUM>) is configured to acquire the sum X<NUM> of brightness values of the area (related area <NUM>) included in the captured image <NUM>. The determination unit 59a (<NUM>) is configured to determine whether the tool condition is satisfied on the basis of the sum X<NUM> of brightness values acquired.

With the above configuration (<NUM>), the determination unit 59a (<NUM>) determines whether the tool condition is satisfied on the basis of the sum X<NUM> of brightness values of the area included in the captured image <NUM>. Therefore, even when the imaging conditions of the tool <NUM> change, it is possible to accurately determine whether the tool condition is satisfied.

For example, if the tool <NUM> is used continuously, the imaging conditions can change due to the workpiece <NUM> adhering to the tool <NUM>. In this case, even if the tool <NUM> to be judged satisfies the tool condition, the brightness value in the captured image <NUM> tends to decrease, which may cause erroneous determination as to whether the tool condition is satisfied. In this regard, in the embodiment where the brightness value acquisition unit 56a acquires the sum X<NUM> of brightness values, even if the workpiece <NUM> adheres to the tool <NUM>, the rate of decrease of the sum X<NUM> of brightness values is small. Therefore, even when the imaging conditions change, the accuracy of determination whether the tool condition is satisfied is maintained.

(<NUM>) According to some aspects of the present disclosure, in any one of the above configurations (<NUM>) to (<NUM>), the tool movement control unit <NUM> is configured to selectively control the robot arm <NUM> to be controlled among a plurality of the robot arms <NUM>. The determination unit <NUM> is configured to determine whether the tool <NUM> attached to the robot arm <NUM> to be controlled satisfies the tool condition.

With the above configuration (<NUM>), the tool movement control unit <NUM> selectively moves the robot arm <NUM> equipped with the tool <NUM> that requires determination regarding the tool condition. Thus, the tool checking device <NUM> can efficiently determine whether the tool condition is satisfied.

(<NUM>) According to some aspects of the present disclosure, in any one of the above configurations (<NUM>) to (<NUM>), the tool checking device <NUM> further includes an image processing unit <NUM> configured to perform, on the captured image <NUM>, image processing associated with the tool condition, and generate a processed image <NUM> in which a related area <NUM> associated with the tool condition is extracted. The determination unit <NUM> is configured to determine whether the tool condition is satisfied, on the basis of the processed image <NUM>.

With the above configuration (<NUM>), the related area <NUM> associated with the tool condition is extracted to generate the processed image <NUM>, and on the basis of the processed image <NUM> generated, the determination unit <NUM> determines whether the tool condition is satisfied. Thus, it is possible to accurately determine whether the tool <NUM> satisfies the tool condition, on the basis of the related area <NUM> associated with the tool condition.

(<NUM>) According to some aspects of the present disclosure, in the above configuration (<NUM>), the image processing unit <NUM> is configured to apply masking to the captured image <NUM> using a reference image <NUM> associated with the tool condition, and generate an image in which the related area <NUM> associated with the tool condition is extracted as the processed image <NUM>.

With the above configuration (<NUM>), the determination unit <NUM> can accurately determine whether the tool <NUM> satisfies the tool condition on the basis of the processed image <NUM> masked.

(<NUM>) A tool checking program <NUM> for a robot arm according to at least one aspect of the present disclosure is configured to cause a computer to execute: a tool movement control step (S15) of controlling the robot arm <NUM> so as to move a tool <NUM> attached to the robot arm <NUM> to a defined position P2; an imaging control step (S17) of controlling an imaging device <NUM> so as to capture an image of the tool <NUM> moved to the defined position P2; and a determination step (S23) of determining whether the tool <NUM> satisfies a tool condition regarding a tool type or tool state that needs to be satisfied, on the basis of a captured image <NUM> imaged by the imaging device <NUM>.

With the above configuration (<NUM>), it is possible to accurately determine whether the tool <NUM> satisfies the tool condition for the same reason as the above (<NUM>).

(<NUM>) A tool checking method for a robot arm according to at least one aspect of the present disclosure includes: a tool movement control step (S15) of controlling the robot arm <NUM> so as to move a tool <NUM> attached to the robot arm <NUM> to a defined position P2; an imaging control step (S17) of controlling an imaging device <NUM> so as to capture an image of the tool <NUM> moved to the defined position P2; and a determination step (S23) of determining whether the tool <NUM> satisfies a tool condition regarding a tool type or tool state that needs to be satisfied, on the basis of a captured image <NUM> imaged by the imaging device <NUM>.

Claim 1:
A workpiece processing system (<NUM>) comprising:
a robot arm (<NUM>) to which a tool (<NUM>) for processing a food product as a workpiece (<NUM>) is attached;
an imaging device (<NUM>) for capturing an image of the workpiece (<NUM>), the robot arm (<NUM>) being configured to process the workpiece (<NUM>) by the tool (<NUM>) based on results of image analysis of the captured image of the workpiece (<NUM>); and
a tool checking device (<NUM>) for checking the tool (<NUM>) attached to the robot arm (<NUM>), the tool checking device (<NUM>) comprising:
a tool movement control unit (<NUM>) configured to control the robot arm (<NUM>) so as to move the tool (<NUM>) attached to the robot arm (<NUM>) to a defined position (P2);
an imaging control unit (<NUM>) configured to control the imaging device (<NUM>) so as to capture an image of the tool (<NUM>) moved to the defined position (P2); and
a determination unit (<NUM>) configured to determine whether the tool (<NUM>) satisfies a tool condition regarding a tool type or tool state that needs to be satisfied, on the basis of
a captured image (<NUM>) of the tool moved to the defined position (P2) imaged by the imaging device (<NUM>).