Patent Description:
Patent Literature <NUM> discloses a robot control system that performs visual servo based on a captured image in which a reflecting mirror reflecting an object is within an imaging range of an imaging unit and a reference image. <CIT> discloses a machine vision camera which observes components to be placed at a selected location on a substrate from a given angle relative to the orthogonal to the substrate through a mirror and then observes the selected location on the substrate from the same angle but with the mirror displaced in order to measure, register and align under-side contact and edge features of the component to corresponding substrate features. <CIT> discloses a technique for enabling high precision positioning of two objects.

The robot control system is configured to be able to image an object from a plurality of directions with one camera and align the object from the plurality of directions by using the reflecting mirror. However, for example, when an object is moved and assembled to a fixed receiving object, it may be difficult to assemble the object to the receiving object unless relative alignment between the object and the receiving object is accurately performed.

An object of the present disclosure is to provide an alignment device capable of more accurately performing relative alignment between a first workpiece and a second workpiece arranged away from the first workpiece.

An alignment device of an example of the present disclosure that aligns a second workpiece with a first workpiece arranged on a work surface while bringing the second workpiece, the second work piece being arranged away from the first workpiece in a first direction intersecting the work surface, close to the first workpiece, includes:.

According to the alignment device, the relative position of the second workpiece with respect to the first workpiece is calculated based on the image of the first workpiece and the image of the mirror image of the second workpiece, which are captured by the image sensor, and feedback control is performed on the moving device based on the calculated position of the second workpiece to align the second workpiece with the first workpiece. With such a configuration, it is possible to realize the alignment device capable of more accurately performing relative alignment between the first workpiece and the second workpiece arranged away from the first workpiece.

Hereinafter, an example of the present disclosure will be described with reference to the accompanying drawings. In the following description, terms indicating specific directions or positions (for example, terms including "up," "down," "right," and "left") are used as necessary, but the use of these terms is to facilitate understanding of the present disclosure with reference to the drawings, and the technical scope of the present disclosure is not limited by the meanings of these terms. Further, the following description is merely exemplary in nature and is not intended to limit the present disclosure, an object for application, or a usage. Furthermore, the drawings are schematic, and ratios of dimensions and the like do not necessarily match actual ones.

As shown in <FIG>, an alignment device <NUM> according to an embodiment of the present disclosure is configured such that a second workpiece <NUM> arranged away from a first workpiece <NUM> in a first direction Z intersecting a work surface <NUM> is allowed to approach and be assembled to the first workpiece <NUM> arranged on the work surface <NUM>. Specifically, the alignment device <NUM> includes a holding device <NUM>, a moving device <NUM> that moves the holding device <NUM>, a mirror member <NUM> arranged adjacent to the first workpiece <NUM>, an image sensor <NUM>, and a control device <NUM> that controls the moving device <NUM>.

In the present embodiment, as an example, the first workpiece <NUM> and the second workpiece <NUM> are configured to be assembled by connecting a connected portion <NUM> of the first workpiece <NUM> and a connecting portion <NUM> of the second workpiece <NUM> in an aligned state. As shown in <FIG>, each of the connected portion <NUM> and the connecting portion <NUM> includes at least one reference point <NUM> and <NUM> that is arranged to face each other and serves as reference for alignment when the second workpiece is assembled to the first workpiece <NUM> on a plane intersecting the first direction Z (that is, the XY plane).

The holding device <NUM> is configured to be able to hold the second workpiece <NUM> in a state where the connecting portion <NUM> of the second workpiece <NUM> faces the connected portion <NUM> of the first workpiece <NUM>. Specifically, the holding device <NUM> includes a connecting member <NUM> connected to the moving device <NUM> in a movable state in the Y direction, and a holding member <NUM> extending from the connecting member <NUM> in the first direction Z. The holding member <NUM> is connected to the connecting member <NUM> in a state of being movable in the first direction Z and being rotatable about the first direction Z. The holding device <NUM> may be, for example, an end effector.

The moving device <NUM> is configured to be able to move the holding device <NUM> toward the first workpiece <NUM>. Specifically, the moving device <NUM> includes a connecting member <NUM> to which the holding device <NUM> is connected, a rail member <NUM> that movably supports the connecting member <NUM> in the X direction, a motor <NUM> that moves the connecting member <NUM> of the moving device <NUM> and the holding member <NUM> of the holding device <NUM>, and an encoder <NUM> that detects the rotation of the motor. The encoder <NUM> is an example of a position detection sensor, and detects the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM>. Information detected by the encoder <NUM> is output to the control device <NUM>. The moving device <NUM> may be, for example, a multi-axis robot arm. In this case, the multi-axis robot arm may include the holding device <NUM>. That is, the holding device <NUM> and the moving device <NUM> may be configured by a multi-axis robot arm.

In the present embodiment, the moving device <NUM> is configured to move only the second workpiece <NUM>, but the moving device is not limited thereto. For example, the moving device may be configured to move the first workpiece <NUM> in the X direction and move the second workpiece <NUM> in the Y direction.

The mirror member <NUM> is arranged adjacent to the first workpiece <NUM> in the second direction X intersecting the first direction Z. The mirror member <NUM> is configured so that the second workpiece <NUM> can be reflected thereon when the second workpiece <NUM> moves from an initial position P1 (shown in <FIG>) away from the first workpiece <NUM> to an assembly position P2 (shown in <FIG>) in contact with the first workpiece <NUM> in the first direction Z. In the present embodiment, the mirror member <NUM> is arranged on the same work surface <NUM> as the first workpiece <NUM>.

The image sensor <NUM> includes, for example, a COMS area sensor or a CCD area sensor, and has an angle of view <NUM> radially extending from a center of a detection surface <NUM> as shown in <FIG>. The image sensor <NUM> is arranged so as to be capable of simultaneously capturing the first workpiece <NUM> and a mirror image <NUM> of the second workpiece <NUM> reflected on the mirror member <NUM> when the holding device <NUM> holding the second workpiece <NUM> is moved toward the first workpiece <NUM> by the moving device <NUM>. In the present embodiment, the image sensor <NUM> is arranged on a straight line L0 passing through the reference point <NUM> of the first workpiece <NUM> and extending in the X direction, and is configured to be able to continuously capture the first workpiece <NUM> and the mirror image <NUM> of the second workpiece <NUM> in the same image.

The position of the image sensor <NUM> may be detected in advance by a design drawing, measurement in advance, or the like. Alternatively, the position of the image sensor <NUM> may be detected in advance based on the position of the second workpiece <NUM> with respect to the first workpiece in the first direction Z and the captured first workpiece <NUM> and the captured mirror image <NUM> of the second workpiece <NUM>. In this case, for example, mirror images <NUM> of the second workpiece <NUM> at two different positions in the first direction Z are captured in advance. Then, the position of the image sensor <NUM> is calculated from the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece and the position of the second workpiece <NUM> in the second direction X from the mirror image <NUM> with respect to the first workpiece <NUM>.

The control device <NUM> includes a CPU that performs calculation and the like, storage media such as a ROM and a RAM that store programs or data necessary for controlling the moving device <NUM>, and an interface that inputs and outputs signals to and from the outside of the alignment device <NUM>.

The control device <NUM> calculates the position of the second workpiece <NUM> with respect to first workpiece <NUM> based on the first workpiece <NUM> and the mirror image <NUM> of the second workpiece <NUM>, which are captured by image sensor <NUM>.

For example, the control device <NUM> calculates the position of the second workpiece <NUM> with respect to the first workpiece <NUM> in the first direction Z based on the information output from the encoder of the moving device <NUM>. Further, the control device <NUM> calculates positions of the reference point <NUM> of the first workpiece <NUM> and a reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> from the first workpiece <NUM> and the mirror image <NUM> of the second workpiece, which are captured by image sensor <NUM>.

The positions of the reference points <NUM> and <NUM> of the workpieces <NUM> and <NUM> are calculated as follows, for example. That is, the control device <NUM> detects "feature points" which are outer shapes of the workpieces <NUM> and <NUM> of detection marks provided in the workpieces <NUM> and <NUM> in advance from the first workpiece <NUM> and the mirror image <NUM> of the second workpiece, which are captured by the image sensor <NUM>. Then, the control device <NUM> calculates the positions of the reference points <NUM> and <NUM> of the workpieces <NUM> and <NUM> based on the detected "feature points". The reference point <NUM> of the first workpiece <NUM> is the reference point <NUM> of the first workpiece <NUM> displayed in the image captured by the image sensor <NUM>, and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> is the reference point <NUM> of the second workpiece <NUM> reflected on the mirror member <NUM>. The reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> are calculated as coordinates on the XY plane orthogonal to the first direction Z, for example. The control device <NUM> performs feedback control of the moving device <NUM> based on the calculated position of the second workpiece <NUM> with respect to the first workpiece <NUM>, and aligns the second workpiece <NUM> with the first workpiece <NUM>.

The control device <NUM> calculates a relative angle of the second workpiece <NUM> with respect to the first workpiece <NUM> from the first workpiece <NUM> and the mirror image <NUM> of the second workpiece, which are captured by the image sensor <NUM>. For the relative angle of the second workpiece <NUM> with respect to the first workpiece <NUM>, for example, as shown in <FIG>, the first workpiece <NUM> and the mirror image <NUM> of the second workpiece <NUM> are projected on the work surface <NUM>. Then, an angle θ of a projection mapping <NUM> of the mirror image <NUM> of the second workpiece <NUM> projected on the work surface <NUM> with respect to a projection mapping <NUM> of the first workpiece <NUM> projected on the work surface <NUM> is calculated as the relative angle of the second workpiece <NUM> with respect to the first workpiece <NUM>.

Specifically, as shown in <FIG>, the control device <NUM> includes a position determination unit <NUM>, a movement control unit <NUM>, a correction unit <NUM>, and a calculation determination unit <NUM>.

The position determination unit <NUM> determines whether or not the second workpiece <NUM> has reached a predetermined position based on the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM> detected by the encoder <NUM> when the second workpiece <NUM> approaches the first workpiece <NUM> in the first direction Z from the initial position P1 (shown in <FIG>). Specifically, the position determination unit <NUM> determines whether or not the second workpiece <NUM> has reached a start position P3 (shown in <FIG>) closer to the first workpiece <NUM> than the initial position P1. Further, the position determination unit <NUM> determines whether or not the second workpiece <NUM> has reached an end position P4 (shown in <FIG>) closer to the first workpiece <NUM> than the start position P3.

The start position P3 is, for example, an upper limit position in the first direction Z at which the image sensor <NUM> can simultaneously image and calculate the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> reflected on the mirror member <NUM>. Further, the end position P4 is, for example, a lower limit position in the first direction Z at which the image sensor <NUM> can simultaneously image and calculate the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> reflected on the mirror member <NUM>. Each of the start position P3 and the end position P4 is determined by, for example, performance of an imaging element used in the image sensor <NUM> or performance of an optical system such as a focal length of a lens and a depth of field.

The movement control unit <NUM> controls the moving device <NUM> to move the holding device <NUM> to bring the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> closer to the reference point <NUM> of the first workpiece <NUM> while the position determination unit <NUM> determines that the second workpiece <NUM> has reached the start position P3 and has not reached the end position P4. The approach path of the reference point <NUM> to the reference point <NUM> may be a straight shortest path, or may be a curved or meandering detour path, for example.

As shown in <FIG>, the correction unit <NUM> corrects each of the image of the first workpiece <NUM> and the image of the mirror image <NUM> of the second workpiece <NUM>, which are captured by the image sensor <NUM>, and converts the corrected images into the projection mappings <NUM> and <NUM> projected on the work surface <NUM>. In the present embodiment, the correction unit <NUM> converts the image of the first workpiece <NUM> and the image of the mirror image <NUM> of the second workpiece <NUM> into the projection mappings <NUM> and <NUM> projected on the work surface <NUM>. However, for example, the correction unit <NUM> may convert the images into projection mappings projected in an optional plane space suitable for alignment of the first workpiece <NUM> and the second workpiece <NUM>.

The correction unit <NUM> corrects a size of the image of the mirror image <NUM> of the second workpiece <NUM> based on the calculated position of the second workpiece <NUM> with respect to the first workpiece <NUM> in the first direction Z.

For example, as shown in <FIG>, when the second workpiece <NUM> is at the initial position P1, the mirror image <NUM> of the second workpiece <NUM> is reflected at a position M1 of the mirror member <NUM>. Further, when the second workpiece <NUM> is at the start position P3 and the end position P4 between the initial position P1 and the assembly position P2, the mirror image <NUM> of the second workpiece <NUM> is reflected at positions M3 and M4 of the mirror member <NUM>, respectively. The image of the mirror image <NUM> of the second workpiece <NUM> gradually decreases from the actual size of the second workpiece <NUM> as being away from the first workpiece <NUM> in the first direction Z. The correction unit <NUM> corrects the size of the image of the mirror image <NUM> of the second workpiece <NUM> to an actual size of the second workpiece <NUM> according to the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM>, which is detected by the encoder <NUM>.

By performing these corrections, the calculation accuracy of the position and angle of the reference point <NUM> of the first workpiece <NUM> and the position and angle of the reference point <NUM> of the second workpiece <NUM> is improved.

The calculation determination unit <NUM> determines whether or not the position of the second workpiece <NUM> with respect to the first workpiece <NUM> can be calculated based on the mirror image <NUM> of the second workpiece <NUM> captured by the image sensor <NUM>. Specifically, the calculation determination unit <NUM> compares an approximation of the shapes of the reference points <NUM> and <NUM> or a steepness of the grayscale change of the reference points <NUM> and <NUM> between the image of the mirror image <NUM> of the second workpiece <NUM> captured in advance and the captured image of the mirror image <NUM> of the second workpiece <NUM>. Then, as a result of such comparison, the calculation determination unit <NUM> determines that the position of the second workpiece <NUM> with respect to the first workpiece <NUM> can be calculated when the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> can be calculated, and determines that the position of the second workpiece <NUM> with respect to one workpiece <NUM> cannot be calculated when the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> cannot be calculated.

Next, an alignment step of aligning the second workpiece <NUM> located at the initial position P1 with the first workpiece <NUM> while moving the second workpiece <NUM> to the assembly position P2 using the alignment device <NUM> will be described. These operations described below are performed by the control device <NUM> executing a predetermined program.

As shown in <FIG>, the control device <NUM> controls the moving device <NUM> to move the holding device <NUM>, and starts the movement of the second workpiece <NUM> located at the initial position P1 toward the first workpiece <NUM> (step S1).

When the second workpiece <NUM> starts to move toward the first workpiece <NUM>, the position determination unit <NUM> determines whether or not the second workpiece <NUM> has reached the start position P3 based on the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM>, which is detected by the encoder <NUM> (step S2). When it is determined that the second workpiece <NUM> has not reached the start position P3, step S2 is repeated until it is determined that the second workpiece <NUM> has reached the start position P3.

When it is determined that the second workpiece <NUM> has reached the start position P3, the control device <NUM> captures the first workpiece <NUM> and the mirror image <NUM> of the second workpiece <NUM> by the image sensor <NUM> while moving the second workpiece <NUM> to the first workpiece <NUM> (step S3).

When the first workpiece <NUM> and the mirror image <NUM> of the second workpiece <NUM> are captured, the calculation determination unit <NUM> determines whether or not the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> can be calculated from the image of the mirror image <NUM> of the second workpiece <NUM> captured by the image sensor <NUM> (step S4). When it is determined that the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> cannot be calculated from the image of the mirror image <NUM> of the second workpiece <NUM> captured by the image sensor <NUM>, the process returns to step S3, and the next first workpiece <NUM> and the next mirror image <NUM> of the second workpiece <NUM> are captured by the image sensor <NUM>.

When it is determined that the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> can be calculated from the image of the mirror image <NUM> of the second workpiece <NUM> captured by the image sensor <NUM>, the correction unit <NUM> corrects each of the captured image of the first workpiece <NUM> and the captured image of the mirror image <NUM> of the second workpiece <NUM> (step S5). Then, based on the corrected image of the first workpiece <NUM> and the corrected image of the mirror image <NUM> of the second workpiece <NUM>, the control device <NUM> calculates the position of the reference point <NUM> of the first workpiece <NUM>, the position of the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM>, and a relative angle θ of the second workpiece <NUM> with respect to the first workpiece <NUM> (step S6).

When the position of the reference point <NUM> of the first workpiece <NUM>, the position of the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM>, and the relative angle θ of the second workpiece <NUM> with respect to the first workpiece <NUM> are calculated, the movement control unit <NUM> controls the moving device <NUM> to move the holding device <NUM> based on the calculated position of the reference point <NUM> of the first workpiece <NUM>, the calculated position of the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM>, and the calculated relative angle θ of the second workpiece <NUM> with respect to the first workpiece <NUM>. As a result, the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> is brought close to the reference point <NUM> of the first workpiece <NUM> (step S7).

After completion of step S7, the position determination unit <NUM> determines whether or not the second workpiece <NUM> has reached the end position P4 based on the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM>, which is detected by the encoder <NUM> (step S8). When it is determined that the second workpiece <NUM> has not reached the end position P4, the process returns to step S3, and the image sensor <NUM> captures the next first workpiece <NUM> and the next mirror image <NUM> of the second workpiece <NUM>.

When it is determined that the second workpiece <NUM> has reached the end position P4, the control device <NUM> determines whether or not a difference between the position of the reference point <NUM> of the first workpiece <NUM> and the position of the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> and a difference between the angle of the reference point of the first workpiece <NUM> and the angle of the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> are equal to or less than a threshold (step S9). When it is determined that the differences in position and angle between the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> are equal to or less than the threshold, the process proceeds to an assembly step of assembling the second workpiece <NUM> to the first workpiece <NUM> (step S10), and the alignment step is ended. On the other hand, when it is determined that the differences in position and angle between the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> are larger than the threshold, the control device <NUM> determines that the alignment of the second workpiece <NUM> with respect to the first workpiece <NUM> has failed (step S11), and ends the alignment step. The threshold is set according to required alignment accuracy of the first workpiece <NUM> and the second workpiece <NUM>, or the like.

As shown in <FIG>, after step S8, the second workpiece <NUM> may be stopped (step S12). In this case, when it is determined in step S9 that the differences in position and angle between the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> are larger than the threshold, the process returns to step S3, and steps S3 to S8, step S12, and step S9 are sequentially repeated until it is determined that the differences in position and angle between the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> are equal to or less than the threshold.

The control device <NUM> may be configured to measure the number of times that it is determined in step S12 that the differences in position and angle between the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> are larger than the threshold. When the measured number of determinations exceeds a predetermined number, the control device <NUM> may determine that the alignment of the second workpiece <NUM> with respect to the first workpiece <NUM> has failed, and end the alignment step.

As described above, according to the alignment device <NUM>, the position of the second workpiece <NUM> with respect to the first workpiece <NUM> is calculated based on the image of the first workpiece <NUM> and the image of the mirror image <NUM> of the second workpiece <NUM>, which are captured by the image sensor <NUM>, and feedback control is performed on the moving device <NUM> based on the calculated position of the second workpiece <NUM> to align the second workpiece <NUM> with the first workpiece <NUM>. That is, the control device <NUM> is configured to perform visual feedback control that repeats feedback control for minimizing a position deviation between the current position and the target position. With such a configuration, it is possible to realize the alignment device <NUM> capable of more accurately performing relative alignment between the first workpiece <NUM> and the second workpiece <NUM> arranged away from the first workpiece <NUM>.

The control device <NUM> includes the position determination unit <NUM> that determines whether or not the second workpiece <NUM> has reached the start position P3 arranged closer to the first workpiece <NUM> than the initial position P1 at which alignment of the second workpiece <NUM> with respect to the first workpiece <NUM> is started, and determines whether or not the second workpiece <NUM> has reached the end position P4 arranged closer to the first workpiece <NUM> than the start position P3 at which alignment of the second workpiece <NUM> with respect to the first workpiece <NUM> is ended, when the second workpiece <NUM> approaches the first workpiece <NUM> in the first direction Z from the initial position P1, based on the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM>, which is detected by the encoder <NUM>, and the movement control unit <NUM> that controls the moving device <NUM> to move the holding device <NUM> while it is determined by the position determination unit <NUM> that the second workpiece <NUM> has reached the start position P3 and has not reached the end position P4 to bring the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> closer to the reference point <NUM> of the first workpiece <NUM>. With such a configuration, it is possible to easily realize the alignment device <NUM> capable of more accurately aligning the second workpiece <NUM> arranged away from the first workpiece <NUM> with respect to the first workpiece <NUM>.

When a plurality of reference points <NUM> and <NUM> are provided in each of the workpieces <NUM> and <NUM>, an inclination of the second workpiece <NUM> with respect to the first workpiece <NUM> can be calculated from the calculated positions of the plurality of reference points <NUM> of the first workpiece <NUM> and the calculated positions of the plurality of reference points <NUM> of the mirror image <NUM> of the second workpiece <NUM>.

The control device <NUM> includes the correction unit <NUM> that corrects each of the image of the first workpiece <NUM> and the image of the mirror image <NUM> of the second workpiece <NUM>, which are captured by the image sensor <NUM>, and converts the images into the projection mappings <NUM> and <NUM> onto the work surface <NUM>. The correction unit <NUM> can enhance the calculation accuracy of the position of the second workpiece <NUM> with respect to the first workpiece <NUM> as compared with a case where the captured first workpiece <NUM> and the captured mirror image <NUM> of the second workpiece <NUM> are not corrected.

The correction unit <NUM> corrects the size of the mirror image <NUM> of the second workpiece <NUM> based on the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM>, which is detected by the encoder <NUM>. With such a configuration, the calculation accuracy of the position of the second workpiece <NUM> with respect to the first workpiece <NUM> can be enhanced as compared with a case where the captured first workpiece <NUM> and the captured mirror image <NUM> of the second workpiece <NUM> are not corrected.

When the holding device <NUM> approaches the first workpiece <NUM> and the image sensor <NUM> cannot simultaneously capture the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM>, the position determination unit <NUM> determines that the second workpiece <NUM> has reached the end position P4. With such a configuration, it is possible to easily realize the alignment device <NUM> capable of more accurately aligning the second workpiece <NUM> arranged away from the first workpiece <NUM> with respect to the first workpiece <NUM>.

In addition, the control device <NUM> includes the calculation determination unit <NUM> that determines whether or not the position of the second workpiece <NUM> with respect to the first workpiece <NUM> can be calculated based on the mirror image <NUM> of the second workpiece <NUM> captured by the image sensor <NUM>. The calculation determination unit <NUM> can avoid, for example, alignment of the second workpiece <NUM> with respect to the first workpiece <NUM> based on an unclear image. As a result, the second workpiece <NUM> can be accurately and efficiently aligned with the first workpiece <NUM>.

The alignment device <NUM> is not limited to the above embodiment as long as the alignment device <NUM> is configured to calculate the position of the second workpiece <NUM> with respect to the first workpiece <NUM> based on the image of the first workpiece <NUM> and the mirror image <NUM> of the second workpiece <NUM>, which are captured by the image sensor <NUM>, and perform feedback control of the moving device <NUM> based on the calculated position of the second workpiece <NUM> to align the second workpiece <NUM> with the first workpiece <NUM>. For example, the correction unit <NUM> and the calculation determination unit <NUM> may be omitted.

The mirror member <NUM> is not limited to be arranged on the work surface <NUM>, and may be arranged, for example, at a position farther from the second workpiece <NUM> than the work surface <NUM> in the first direction Z. The mirror member <NUM> may be configured to be movable in the first direction Z when the second workpiece <NUM> is moved toward the first workpiece <NUM>. With this configuration, it is possible to expand a range in which the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM> can be simultaneously imaged.

Various embodiments of the present disclosure have been described above in detail with reference to the drawings. Finally, various aspects of the present disclosure will be described. In the following description, as an example, reference numerals are also added.

An alignment device <NUM> of a first aspect of the present disclosure that aligns a second workpiece <NUM> with a first workpiece <NUM> arranged on a work surface <NUM> while bringing the second workpiece <NUM> close to the first workpiece <NUM>, the second work piece <NUM> being arranged away from the first workpiece <NUM> in a first direction Z intersecting the work surface <NUM>, includes:.

According to the alignment device <NUM> of the first aspect, the relative position of the second workpiece <NUM> with respect to the first workpiece <NUM> is calculated based on the image of the first workpiece <NUM> and the image of the mirror image <NUM> of the second workpiece <NUM>, which are captured by the image sensor <NUM>, and feedback control is performed on the moving device <NUM> based on the calculated position of the second workpiece <NUM> to align the second workpiece <NUM> with the first workpiece <NUM>. With such a configuration, it is possible to realize the alignment device <NUM> capable of more accurately performing relative alignment between the first workpiece <NUM> and the second workpiece <NUM> arranged away from the first workpiece <NUM>.

In the alignment device <NUM> of a second aspect of the present disclosure,.

According to the alignment device <NUM> of the second aspect, it is possible to easily realize the alignment device <NUM> capable of more accurately aligning the second workpiece <NUM> arranged away from the first workpiece <NUM> with respect to the first workpiece <NUM>.

In the alignment device <NUM> of a third aspect of the present disclosure,
the control device <NUM> includes a correction unit <NUM> that corrects each of an image of the first workpiece <NUM> and an image of the mirror image <NUM> of the second workpiece <NUM>, which are captured by the image sensor <NUM>, and converts the images into projection mappings <NUM> and <NUM> onto an optional plane <NUM>.

According to the alignment device <NUM> of the third aspect, the calculation accuracy of the position of the second workpiece <NUM> with respect to the first workpiece <NUM> can be enhanced as compared with a case where the captured image of the first workpiece <NUM> and the captured image of the mirror image <NUM> of the second workpiece <NUM> are not corrected.

In the alignment device <NUM> of a fourth aspect of the present disclosure,
the correction unit <NUM> corrects a size of the image of the mirror image <NUM> of the second workpiece <NUM> based on the position of the second workpiece <NUM> in the first direction Z with respect to the first workpiece <NUM>, which is detected by the position detection sensor <NUM>.

According to the alignment device of the fourth aspect, the calculation accuracy of the position of the second workpiece <NUM> with respect to the first workpiece <NUM> can be enhanced as compared with a case where the captured image of the mirror image <NUM> of the second workpiece <NUM> is not corrected.

In the alignment device <NUM> of a fifth aspect of the present disclosure,
the position determination unit <NUM> determines that the second workpiece <NUM> has reached the end position P4 when the holding device <NUM> approaches the first workpiece <NUM> and the image sensor <NUM> cannot simultaneously capture the reference point <NUM> of the first workpiece <NUM> and the reference point <NUM> of the mirror image <NUM> of the second workpiece <NUM>.

According to the alignment device <NUM> of the fifth aspect, it is possible to easily realize the alignment device <NUM> capable of more accurately aligning the second workpiece <NUM> arranged away from the first workpiece <NUM> with respect to the first workpiece <NUM>.

In the alignment device <NUM> of a sixth aspect of the present disclosure,
the control device <NUM> includes a calculation determination unit <NUM> that determines whether or not the position of the second workpiece <NUM> with respect to the first workpiece <NUM> can be calculated based on the mirror image <NUM> of the second workpiece <NUM> captured by the image sensor <NUM>.

According to the alignment device of the sixth aspect, for example, alignment of the second workpiece <NUM> with respect to the first workpiece <NUM> based on an unclear image can be avoided. As a result, the second workpiece <NUM> can be accurately and efficiently aligned with the first workpiece <NUM>.

By appropriately combining any embodiments or modifications among the various embodiments or modifications, the effects of the respective embodiments or modifications can be achieved. In addition, combinations of embodiments, combinations of examples, or combinations of embodiments and examples are possible, and combinations of features in different embodiments or examples are also possible.

Claim 1:
An alignment device (<NUM>) configured to align
a second workpiece with a first workpiece arranged on a work surface while bringing the second workpiece close to the first workpiece, the second work piece being arranged away from the first workpiece in a first direction intersecting the work surface, the alignment device (<NUM>) comprising
a holding device (<NUM>) configured to hold the second workpiece;
a moving device (<NUM>) configured to move the holding device (<NUM>) toward the first workpiece;
a mirror member (<NUM>) configured to reflect the second workpiece, the mirror member (<NUM>) being arranged adjacent to the first workpiece in a second direction intersecting the first direction;
an image sensor (<NUM>) configured to simultaneously and continuously capture the first workpiece and a mirror image of the second workpiece reflected on the mirror member (<NUM>) when the holding device (<NUM>) in a state of holding the second workpiece is configured to be moved toward the first workpiece by the moving device (<NUM>); and
a control device (<NUM>) that is configured to calculate a position of the second workpiece with respect to the first workpiece based on the first workpiece and the mirror image of the second workpiece, which are captured by the image sensor (<NUM>), and is configured to perform feedback control of the moving device based on the calculated position of the second workpiece to align the second workpiece with the first workpiece.