WO2025126360A1 - Design assisting device and design assisting method - Google Patents

Abstract

This design assisting device for assisting safety design of a work system including a robot comprises: a model display processing unit that displays, on a predetermined display screen, a three-dimensional model in which the robot and surrounding objects are placed in a virtual space; a sensor display processing unit that displays a safety sensor in the three-dimensional model such that the safety sensor is placed in a position and orientation based on a placement instruction provided by a designer, the safety sensor monitoring the surroundings of the robot; and an area display processing unit that displays, in the three-dimensional model, a detection area of the safety sensor placed in the three-dimensional model.

Description

Design support device and design support method

This specification discloses a design support device and a design support method.

　Conventionally, there have been proposals to generate a three-dimensional model in which a robot and peripheral elements (placement objects) are arranged in a virtual space, and to verify the robot's operation and safety. For example, Patent Document 1 describes including tools that exist in the real environment as peripheral elements in the three-dimensional model, and checking whether the robot and the tools interfere with each other.

JP 2022-137797 A

As mentioned in Patent Document 1, verifying the safety of robots is considered an important issue. Furthermore, in recent years, collaborative robots that work in the same space as workers have been increasingly introduced, so there is a need to improve safety not only for peripheral elements but also for nearby workers. However, this can require a large amount of man-hours from designers, placing a heavy burden on them.

The primary objective of this disclosure is to improve the safety of workers around robots while reducing the burden on designers.

This disclosure takes the following steps to achieve the above-mentioned primary objective:

The design support device of the present disclosure is
A design support device for supporting a safety design of a work system including a robot, comprising:
a model display processing unit that displays a three-dimensional model of the robot and surrounding objects arranged in a virtual space on a predetermined display screen;
a sensor display processing unit that displays, within the three-dimensional model, safety sensors that monitor the periphery of the robot so as to be arranged at positions and in orientations based on arrangement instructions from a designer;
an area display processing unit that displays, within the three-dimensional model, a detection area of the safety sensor disposed within the three-dimensional model;
The gist of the project is to provide the following:

In the design support device disclosed herein, safety sensors that monitor the area around the robot are displayed in a three-dimensional model in which the robot and surrounding objects are arranged in a virtual space, with the safety sensors positioned in a position and orientation based on the designer's placement instructions. The detection area of the safety sensor is also displayed in the three-dimensional model. This allows the designer to easily optimize the detection area and placement position of the safety sensor, making it possible to appropriately place the safety sensor around the robot. This makes it possible to improve the safety of workers around the robot while reducing the burden on the designer.

FIG. 2 is a schematic diagram of a safety sensor 10 and a PC 20. 1 is a schematic configuration diagram of a work system 40 including a safety sensor 10 and a robot 50. FIG. 11 is a flowchart showing an example of a first half of a safety design support process. 10 is a flowchart showing an example of a second half of the safety design support process. FIG. 4 is an explanatory diagram showing an example of a safety design support screen 70. 11 is a flowchart showing an example of a hazard display process. FIG. 4 is an explanatory diagram showing an example of a movable area X. FIG. 4 is an explanatory diagram showing an example of an intrusion area Y. FIG. 4 is an explanatory diagram showing an example of an overlapping region Z. FIG. 4 is an explanatory diagram showing an example of a hazard D. FIG. 4 is an explanatory diagram showing an example of a state in which the safety sensor 10 is arranged. FIG. 2 is an explanatory diagram showing an example of a detection area A of the safety sensor 10. FIG. 11 is an explanatory diagram showing an example of a state in which the range of a detection area A has been changed. FIG. 4 is an explanatory diagram showing an example of how a movable area X and a detection area A are displayed.

An embodiment of the present disclosure will be described with reference to the drawings. FIG. 1 is a schematic diagram of a safety sensor 10 and a PC 20. FIG. 2 is a schematic diagram of a work system 40 including the safety sensor 10 and a robot 50. In this embodiment, the left-right direction, the front-rear direction, and the up-down direction are defined as shown in FIG. 2.

The safety sensor 10 comprises a control unit 11 having a CPU, ROM, RAM, etc., a sensor unit 12 that detects surrounding objects, and a communication unit 13 that communicates with external devices such as a PC 20 or a robot 50. The sensor unit 12 of the safety sensor 10 is, for example, a laser or millimeter wave radar. The sensor unit 12 monitors the presence or absence of a worker M within a set detection area (monitoring area) A within a detectable area (maximum detection area) that is a roughly sector-shaped area when viewed from above and in which objects can be detected.

The PC 20 is a general-purpose computer that supports the manager of the work system 40, the worker M, and other designers in carrying out various safety designs, including the setting of the detection area A of the safety sensor 10. The PC 20 includes a control unit 21 having a CPU, ROM, RAM, and other components, a storage unit 22 such as a HDD that stores various application programs and various data, and a communication unit 23 that communicates with external devices connected via a network and with the safety sensor 10 connected via a communication line 18. For example, a USB cable is used as the communication line 18. The PC 20 and the safety sensor 10 may be connected to each other so that they can communicate wirelessly. The PC 20 also includes an input unit 27 such as a keyboard or touchpad through which the manager, the worker M, and other designers input various information, and a display screen 28 such as a liquid crystal display. The PC 20 of this embodiment is capable of constructing a three-dimensional model MD of the work system 40 in a virtual space using a digital twin, and performing various simulations and safety designs using the three-dimensional model MD.

The work system 40 includes, for example, a robot 50, a robot stand 41 on which the robot 50 is arranged, a conveyor device 43, a mounting table 45, and one or more safety sensors 10. The conveyor device 43 and the mounting table 45 are arranged on opposite sides of the left and right direction with the robot 50 sandwiched between them. The conveyor device 43 includes a roller conveyor 43a and an end table 43b. The roller conveyor 43a includes multiple rollers, and conveys the item P in the left and right direction by transmitting the power of a motor (not shown) to each roller to rotate them. The end table 43b is provided at both ends of the conveyor device 43 in the left and right direction (only one end is shown in FIG. 2) and is used as a temporary placement location for the item P before or after transportation. The mounting table 45 has an upper surface divided into multiple placement areas 45a, and the item P is placed on each placement area 45a by the worker M or the robot 50. In addition, pillars 47 and the like are also arranged within the work system 40. The robot stand 41, the conveyor device 43, the mounting stand 45, and the pillars 47 are also referred to as objects (fixed objects).

The robot 50 includes a vertical articulated robot arm 52 in which multiple links are rotatably connected via joints, an end effector 54 as a work tool that can be attached to and detached from the tip link of the robot arm 52, and a control unit and an imaging unit (not shown). The end effector 54 may be an electromagnetic chuck, a mechanical chuck, or a suction nozzle, and is selected according to the shape and material of the article P. In the example of FIG. 2, a mechanical chuck having a pair of chuck jaws that can be opened and closed is attached. The robot 50 grasps a knob portion (projection) Pa formed on the top surface of the article P with the mechanical chuck and transfers the article P between the conveyor device 43 and the placement table 45. The control unit of the robot 50 inputs detection signals from an encoder that detects the rotation angle of each joint of the robot arm 52, detection signals from the safety sensor 10, images captured by the imaging unit, and the like, and controls the operation of the robot arm 52 and the end effector 54.

Here, in the work system 40, a worker M may work around the robot 50. That is, the robot 50 of the work system 40 is used as a collaborative robot that works in the same work space as the worker M. In the work system 40, a plurality of safety sensors 10 are arranged to improve the safety of the worker M around the robot 50. Although three safety sensors 10 are shown in FIG. 2, for example, four safety sensors 10 are arranged on the robot stand 41 so as to monitor the entire circumference of the robot 50 in four directions, front, back, left and right. The arrangement positions, orientations and detection area A of these safety sensors 10 are each set as part of the safety design of the work system 40. FIG. 3 is a flowchart showing an example of a safety design support process. This process is executed by the control unit 21 of the PC 20.

In the safety design support process, the control unit 21 generates a three-dimensional model MD including the robot 50 and its surrounding objects such as the robot stand 41, the conveyor device 43, the mounting table 45, and the pillars 47, and displays it on the safety design support screen 70 on the display screen 28 (S100). The control unit 21 acquires, for example, design information and three-dimensional CAD data including the size of the robot 50 and its surrounding objects, placement information regarding the placement position, and operation information including the operating range and operating speed of each joint of the robot arm 52 of the robot 50, and the type and operation of the end effector 53, and generates and displays the three-dimensional model MD in virtual space.

5 is an explanatory diagram showing an example of a safety design support screen 70. The safety design support screen 70 displays a model display field 71 and various buttons. The model display field 71 displays a three-dimensional model MD including the robot 50 of the work system 40 and surrounding objects. The various buttons displayed are a sensor placement button 72, a movement/intrusion area display button 73, a parameter setting button 74, a hazard source display button 75, a save button 76, an output button 77, and an end button 78. In addition, an instruction pointer 79 that the designer can operate via the input unit 27 is also displayed. The sensor placement button 72 is a button for instructing the placement of the safety sensor 10. The movement/intrusion area display button 73 is a button for switching and displaying each area such as the movement area X of the robot 50, the intrusion area Y of the worker M, and the overlap area Z of the movement area X and the intrusion area Y, and each time it is operated, the display and non-display of one of the three areas are switched in sequence. The parameter setting button 74 is a button for setting parameters that define the detection area of the safety sensor 10. Details of the parameters will be described later. The hazard display button 75 is a button for displaying hazards D in the overlapping area Z, and switches between displaying and hiding one or more hazards D each time it is operated. The save button 76 is a button for saving the state displayed in the model display field 71. The output button 77 is a button for outputting setting information such as the set parameters to the safety sensor 10. The end button 78 is a button for ending the safety design. The instruction pointer 79 is used to operate various buttons, set various parameters, move the safety sensor 10 within the three-dimensional model MD, and operate the robot arm 52 of the robot 50.

Next, the control unit 21 determines whether the hazard display button 75 on the safety design support screen 70 has been operated (S105), and if it determines that the hazard display button 75 has been operated, executes the hazard display process (S110).

6 is a flowchart showing an example of the hazard display process. In the hazard display process, the control unit 21 determines whether the display of the hazard D has been turned on (S200), and proceeds to S245 if it is determined that the display of the hazard D has not been turned on. The control unit 21 determines that the display of the hazard D has been turned on if the hazard display button 75 is operated when the hazard D is not displayed in the three-dimensional model MD of the safety design support screen 70. The control unit 21 also determines that the display of the hazard D has been turned off if the hazard display button 75 is operated when the hazard D is displayed in the three-dimensional model MD of the safety design support screen 70. When the control unit 21 determines that the display of the hazard D has been turned on for the first time in the displayed three-dimensional model MD, it sets the movable area X of the robot 50 and the entry area Y of the worker M (S205). If the hazard D for the displayed three-dimensional model MD has already been set, the control unit 21 skips steps S205 to S235 and proceeds to step S240, where it displays the hazard D as described below.

7 is an explanatory diagram showing an example of the movable area X. The movable area X is set, for example, to an approximately hemispherical spatial area based on the movement trajectory of the end effector 54 attached to the robot 50. In setting the movable area X, the control unit 21 calculates the movement trajectory along which the end effector 54 of the robot 50 can move based on the positioning information and operation information of the robot 50, and sets the approximately hemispherical spatial area formed by the movement trajectory as the movable area X. FIG. 8 is an explanatory diagram showing an example of the intrusion area Y. The colored area in FIG. 8 indicates the area of the bottom surface of the intrusion area Y. The intrusion area Y includes not only the area along which the worker M can move, such as the movement line of the worker M, but also the area on the robot platform 41 into which parts of the body of the worker M, such as the hands and arms, can enter. For this reason, the control unit 21 sets the intrusion area Y to a spatial area whose height is a height that the hand of the worker M can reach from the bottom surface, as shown by the dotted line in FIG. 8. In the example of FIG. 8, the area above the end table 43b of the conveyor device 43 and the area above the placement area 45a of the placement table 45 are excluded from the entry area Y, but these areas may be included.

Next, the control unit 21 extracts interference points and gap points from the overlap area Z where the movable area X and the intrusion area Y overlap (S210). FIG. 9 is an explanatory diagram showing an example of the overlap area Z. The overlap area Z is set as an area where the movable area X and the intrusion area Y overlap. The hatched area in FIG. 9 indicates the area of the bottom surface of the overlap area Z. The overlap area Z includes the area around the robot 50 (robot stand 41), the area on the robot stand 41, the area on the end table 43b of the conveyor device 43, and a part of the area on the placement area 45a of the placement table 45. The interference points are areas where a part of the body of the worker M may interfere (contact) with the robot 50 (robot arm 52, end effector 54) during operation. The gap points are areas where a gap is formed where a part of the body of the worker M may enter, such as the joint of the robot arm 52 of the robot 50.

Then, the control unit 21 determines whether there is an interference area in the overlap area Z (S215), and if it determines that there is no interference area, the process proceeds to S225. As described above, since the robot 50 is used as a collaborative robot, it is usually determined that there is an interference area in S215. If the control unit 21 determines that there is an interference area, it sets a risk level based on the shape, material, and operating speed of the robot 50 at the interference area (S220), and proceeds to S225. If there are multiple interference areas, the control unit 21 sets a risk level for each interference area. In S220, the risk levels are set so that the sharper the shape, the harder the material, and the faster the operating speed. For this reason, for example, if a mechanical chuck is attached as the end effector 54, the risk level is set higher because the shape is sharper and the material is harder than the suction nozzle. The control unit 21 may set the risk level based on at least one of the shape, material, and operating speed of the robot 50 at the interference point.

Furthermore, the control unit 21 determines whether there is a gap in the overlapping region Z (S225), and if it determines that there is no gap, proceeds to S235. If the control unit 21 determines that there is a gap, it sets a risk level based on the gap dimension of the robot 50 at the gap (S230) and proceeds to S235. In S230, if the gap dimension is large enough that the worker M will not get his fingers or hands caught, the risk level is set low, and if the gap dimension is small enough that the worker M will get his fingers or hands caught, the risk level is set high. In addition, if the gap dimension changes as the robot 50 operates, the risk level is set based on whether the changing dimensional range includes a small gap dimension that will get a finger or hand caught. The risk level of the gap may also be set by taking into consideration the shape and material of the robot 50 that constitutes the gap in the same manner as the interference area.

Then, the control unit 21 determines whether there are any locations where the danger level is equal to or greater than the reference value (S235), and if it determines that there are no locations where the danger level is equal to or greater than the reference value, proceeds to S245. On the other hand, if the control unit 21 determines that there are any locations where the danger level is equal to or greater than the reference value, it sets the location as danger source D and displays it on the three-dimensional model MD (S240), and proceeds to S245. Next, the control unit 21 determines whether the display of danger source D has been turned off (S245), and if it determines that it has not been turned off, it terminates this processing. If the control unit 21 determines that the display of danger source D has been turned off, it erases the display of danger source D that was being displayed on the three-dimensional model MD (S250), and terminates this processing.

10 is an explanatory diagram showing an example of a hazard D, in which two hazards D1 and D2 are displayed. The hazard D1 is an interference point at the tip of the end effector 54 of the robot 50. The hazard D2 is a gap at the joint of the robot arm 52 of the robot 50. Note that gaps at other joints are not set as hazards D because, for example, the gap dimensions are too large to pinch the hand of the operator M even when the robot arm 52 is operated, or the gap dimensions are too small to allow the hand of the operator M to enter. In this way, the hazard D is displayed on the safety design support screen 70, so the designer can easily grasp the hazard D. Note that by clicking on the hazards D1 and D2 surrounded by dotted lines, the degree of hazard may be displayed, or the factors that increased the degree of hazard, such as the material and the gap dimensions, may be displayed.

In the safety design support process of FIG. 3, the control unit 21 executes the hazard display process in S110, or when it determines in S105 that the hazard display button 75 has not been operated, it determines whether or not the placement of the safety sensor 10 has been instructed based on whether or not the sensor placement button 72 has been operated (S115). When the control unit 21 determines that the placement of the safety sensor 10 has not been instructed, it proceeds to S125. When the control unit 21 determines that the placement of the safety sensor 10 has been instructed, it displays the safety sensor 10 in the three-dimensional model MD so that the safety sensor 10 is placed in a position and orientation based on the placement instruction (S120). In addition, the control unit 21 determines whether or not the display of the detection area A of the placed safety sensor 10 has been instructed (turned on) (S125), and when it determines that the display has been instructed, it displays the detection area A in the three-dimensional model MD (S130). On the other hand, when the control unit 21 determines that the display of the detection area A has not been instructed, it makes the detection area A non-displayable (S135) and proceeds to S150.

11 is an explanatory diagram showing an example of how the safety sensor 10 is arranged in the three-dimensional model MD. The designer can move and arrange the safety sensor 10 to a desired position in the model display field 71 by, for example, dragging and dropping the safety sensor 10 in the model display field 71 using the instruction pointer 79 of the safety design support screen 70. In addition, when any safety sensor 10 is selected in the model display field 71 on the safety design support screen 70, a setting dialog 72a for setting the position, angle, etc. of the safety sensor 10 is also displayed. In the setting dialog 72a, the position coordinates in the X direction (horizontal direction) and Y direction (vertical direction) of the safety sensor 10, and the orientation (angle) in the horizontal and vertical directions can be set. That is, the arrangement position of the safety sensor 10 can be set by operating the instruction pointer 79 or by specifying the position coordinates. In addition, in the setting dialog 72a, it is also possible to turn on or off the display of the detection area A of the selected safety sensor 10 and to add a new safety sensor 10. For example, if a blank area on the safety design support screen 70 is clicked, the settings dialog 72a will be hidden.

12 is an explanatory diagram showing an example of the detection area A of the safety sensor 10. In this embodiment, the detection area A includes a first detection area A1 on the side closer to the safety sensor 10 and a second detection area A2 on the side farther from the safety sensor 10. The first detection area A1 is, for example, an area up to a first distance (predetermined distance) from the safety sensor 10, and is an area in which the operation of the robot 50 is stopped when a worker M or the like is detected. The second detection area A2 is, for example, an area from the safety sensor 10 between the first distance and the second distance, and is an area in which the operation speed of the robot 50 is slowed down when a worker M or the like is detected. The control unit 21 displays the areas on the safety design support screen 70 in different display modes, such as different display colors, so that the designer can distinguish each area. The detection area A is not limited to two, and may be divided into three or more areas. Although not shown in the figure, the designer may be able to set the boundaries of each area, such as the first distance that is the boundary between the first detection area A1 and the second detection area A2.

When detection area A is thus displayed, the control unit 21 determines whether parameter setting has been instructed based on whether the parameter setting button 74 has been operated (S140), and if it determines that no instruction has been given, proceeds to S150. If the control unit 21 determines that parameter setting has been instructed, it changes detection area A to a detection range according to the set parameters (S145), and proceeds to S150.

13 is an explanatory diagram showing an example of how the range of the detection area A has been changed. As shown in the figure, when the parameter setting button 74 is operated, a setting dialog 74a for setting the range of the detection area A is displayed. In the setting dialog 74a, for example, parameters such as "distance", "width", "horizontal angle", and "vertical angle" can be set by moving the slider with the instruction pointer 79. "Distance" is a detection distance corresponding to the radius of the approximately sector-shaped detection area A centered on the safety sensor 10, and a lower limit value and an upper limit value can be set. For example, a designer can set the area from the safety sensor 10 to the lower limit value as a non-detection area by setting the lower limit value to a value other than 0. "Width" is a horizontal (left and right) detection width set by a pair of parallel lines centered on the safety sensor 10. The inside of this detection width becomes the detection area, and the outside of the detection width becomes the non-detection area. "Horizontal angle" determines the horizontal central angle of the detection area A, that is, the horizontal spread angle. "Vertical angle" determines the central angle in the vertical direction of detection area A, that is, the spread angle in the vertical direction. In FIG. 13, for example, the "horizontal angle" of the setting dialog 74a is changed to be narrower, and a detection area A with a narrower horizontal central angle than the detection area A in FIG. 12 is displayed. Note that, for example, when a blank area of the safety design support screen 70 is clicked, the setting dialog 74a is hidden.

The control unit 21 then determines whether or not display of the movable area X or the intrusion area Y has been instructed based on whether the movable/intrusion area display button 73 has been operated (S150), and if it determines that no instruction has been given, proceeds to S160. If the control unit 21 determines that display has been instructed, it displays either the movable area X of the robot 50, the intrusion area Y of the worker M, or the overlap area Z of the movable area X and the intrusion area Y (S155). As described above, each time the movable/intrusion area display button 73 is operated, the display of one of the three areas is switched in sequence between not displaying any area and not displaying any area. In addition, the three areas that are set in the same way as in S205 of the danger level display process are displayed.

FIG. 14 is an explanatory diagram showing an example of how movable area X and detection area A are displayed. For example, when detection area A is displayed in S130, movable area X is displayed in S155, so that both movable area X and detection area A are displayed. This allows the designer to easily check whether detection area A is appropriate for movable area X. In addition, with movable area X and detection area A displayed together, the designer can optimize the range of detection area A to match the range of movable area X by changing the settings of "distance," "width," "horizontal angle," and "vertical angle" of detection area A in the setting dialog 74a.

Then, the control unit 21 determines whether or not an output to the safety sensor 10 has been instructed based on whether the output button 77 has been operated (S160), and if it determines that an instruction has not been given, proceeds to S170. If the control unit 21 determines that an output has been instructed, it outputs the setting information of the detection area A being displayed, i.e., the setting values of each parameter, to the connected safety sensor 10 (S165), and proceeds to S170.

Then, the control unit 21 determines whether or not an end command has been issued based on whether the end button 78 has been operated (S170), and if it determines that an end command has not been issued, the process returns to S105. If the control unit 21 determines that an end command has been issued, it terminates this process. Although not shown in FIGS. 3 and 4, if the control unit 21 determines that a save command has been issued based on the operation of the save button 76, it saves the state being displayed in the model display area 71 in the memory unit 22. The designer can read out the saved content via an operation on a read screen (not shown) and redesign it on the safety design support screen 70.

Here, the correspondence between the components of this embodiment and the components of this disclosure will be clarified. The control unit 21 that executes S100 of the safety design support processing of this embodiment corresponds to the model display processing unit of this disclosure, the control unit 21 that executes S120 of the same processing corresponds to the sensor display processing unit, and the control unit 21 that executes S130 of the same processing corresponds to the area display processing unit. The control unit 21 that executes S165 of the same processing corresponds to the output unit. The control unit 21 that executes S205 of the hazard display processing and S155 of the safety design support processing corresponds to the area setting unit, and the control unit 21 that executes S210 to S240 of the hazard display processing corresponds to the hazard display processing unit. Note that in this embodiment, an example of the design support method of this disclosure is also clarified by explaining the operation of the PC 20.

In the above-described embodiment, the PC 20 (design support device) displays the safety sensor 10 in a position and orientation based on the designer's placement instructions within the three-dimensional model MD in which the robot 50 and surrounding objects (41, 43, 45, 47) are placed in a virtual space. The detection area A of the safety sensor 10 is also displayed within the three-dimensional model MD. This allows the designer to easily check the detection area A of the safety sensor 10 while appropriately changing the placement position and orientation of the safety sensor 10. That is, the designer can easily optimize the detection area A and placement position of the safety sensor 10. In addition, the safety sensor 10 can be appropriately placed around the robot 50 based on the position and orientation of the safety sensor 10 optimized by the PC 20. Therefore, the burden on the designer can be significantly reduced compared to when the designer adjusts the detection area A while appropriately changing the placement position and orientation of the safety sensor 10 on-site (the installation location of the work system 40). Therefore, the safety of the worker M around the robot 50 can be improved while reducing the burden on the designer.

In addition, the PC 20 displays the detection area A so that it is a detection range based on the setting information including the designer's placement instructions and at least one of the detection distance ("distance"), detection angle ("horizontal angle", "vertical angle"), and non-detection area ("width") set in the safety sensor 10. This allows the designer to easily set an appropriate range for the detection area A, further improving the safety of the worker M.

Furthermore, the detection area A has multiple areas (first detection area A1, second detection area A2) that are divided so that the robot 50 responds differently when the safety sensor 10 detects an object (including the worker M). The PC 20 displays the detection area A so that the multiple areas can be distinguished. This allows the designer to easily check the multiple areas and set the detection area A more appropriately, thereby further improving the safety of the worker M.

The PC 20 can also display the movable area X of the robot 50, based on the position information and operation information of the robot 50, together with the detection area A of the safety sensor 10, in the three-dimensional model MD. This allows the designer to easily check whether the detection area A is appropriate for the movable area X.

The PC 20 is also configured to be able to communicate with the safety sensor 10 via a communication line 18 (wired), and outputs the setting information of the detection area A displayed on the safety design support screen 70 (model display area 71) to the connected safety sensor 10 based on an output instruction from the designer. This allows the designer to further reduce the burden on the designer, as all he or she needs to do is check the displayed detection area A and give an output instruction.

The PC 20 also sets within the three-dimensional model MD a movable area X of the robot 50 and an entry area Y into which at least part of the worker's body can enter. The PC 20 then determines whether or not there is a hazard D within an overlapping area Z between the movable area X and the entry area Y, and displays the hazard D within the three-dimensional model MD if it determines that there is a hazard D. This allows the designer to easily grasp the hazard D, enabling the placement of the safety sensor 10 and the setting of the detection area A to be carried out more appropriately.

The PC 20 also extracts from within the overlapping area Z any part of the body of the worker M that may come into contact with the robot 50 or may be pinched by the robot 50, and determines whether or not that part is a hazard D based on at least one of the shape, material, dimensions, and operating speed of that part. This makes it possible to extract hazard D with simple processing and have the designer confirm it.

It goes without saying that this disclosure is in no way limited to the above-described embodiments, and can be implemented in various forms as long as they fall within the technical scope of this disclosure.

In the embodiment, the hazard D is displayed within the three-dimensional model MD, but this is not limited to the above, and the hazard D does not have to be displayed within the three-dimensional model MD, and steps S105 and S110 of the safety design support process may be omitted.

In the embodiment, the PC 20 outputs the setting information of the detection area A to the safety sensor 10, but this is not limited thereto, and the setting information of the detection area A does not have to be output to the safety sensor 10, and steps S160 and S165 of the safety design support process may be omitted.

In the embodiment, the PC 20 displays either the movable area X of the robot 50, the entry area Y of the worker M, or the overlap area Z together with the detection area A in the three-dimensional model MD, but this is not limited to the above. The PC 20 must be able to display at least the movable area X of the robot 50 together with the detection area A in the three-dimensional model MD. Alternatively, the PC 20 does not need to display the movable area X of the robot 50, etc. together with the detection area A in the three-dimensional model MD, and steps S150 and S155 of the safety design support process may be omitted.

In the embodiment, the PC 20 displays the detection area A so that multiple areas (first detection area A1, second detection area A2) can be distinguished, but this is not limited, and the display may be switchable between a display in which multiple areas can be distinguished and a display in which they cannot be distinguished. Furthermore, the PC 20 does not need to display multiple areas so that they can be distinguished. Alternatively, the safety sensor 10 is not limited to having multiple areas, and may not have multiple areas.

In the embodiment, the PC 20 displays the detection area A so that it is a detection range based on the placement instructions by the designer and setting information including the detection distance, detection angle, and non-detection area set for the safety sensor 10, but this is not limited to the above. For example, the PC 20 may display the detection area so that it is a detection range based on the placement instructions by the designer and the default detection distance and detection angle of the safety sensor 10. That is, the PC 20 may display the safety sensor 10 in the three-dimensional model MD at a position and orientation based on at least the placement instructions, and display the default detectable area of the safety sensor 10 in the three-dimensional model MD. Also, while the PC 20 has been exemplified as a design support device, a smartphone, tablet terminal, etc. may also be used.

In the embodiment, the hazard display process is performed in the safety design support process that displays and sets the detection area A of the safety sensor 10, but the present invention is not limited to this, and the hazard display process may be performed independently of the display and setting of the detection area A of the safety sensor 10. In other words, the design support device disclosed herein may be configured as follows.

In other words, the second design support device disclosed herein is a design support device that supports the safety design of a work system including a robot, and is provided with a model display processing unit that displays a three-dimensional model in which the robot and surrounding objects are arranged in a virtual space on a specified display screen, an area setting unit that sets, within the three-dimensional model, a movable area of the robot and an entry area into which at least a part of the worker's body can enter, and a hazard display processing unit that determines the presence or absence of a hazard within an overlapping area between the movable area and the entry area, and displays the hazard within the three-dimensional model if it is determined that the hazard exists.

In the second design support device disclosed herein, a movable area X of the robot 50 and an entry area Y into which at least part of the body of the worker M can enter are set within a three-dimensional model MD in which the robot 50 and surrounding objects (41, 43, 45, 47) are arranged in a virtual space. In addition, the presence or absence of a hazard D is determined within an overlapping area Z between the movable area X and the entry area Y, and if it is determined that a hazard D exists, the hazard D is displayed within the three-dimensional model MD. This allows the designer to easily check for the hazard D in the work system 40 and respond appropriately. Therefore, it is possible to improve the safety of the worker M around the robot 50 while reducing the burden on the designer.

This specification also discloses the technical idea of changing the "design support device according to claim 1 or 2" in claim 4 at the time of the application to "design support device according to any one of claims 1 to 3," the technical idea of changing the "design support device according to claim 1 or 2" in claim 5 at the time of the application to "design support device according to any one of claims 1 to 4," and the technical idea of changing the "design support device according to claim 1" in claim 6 at the time of the application to "design support device according to any one of claims 1 to 5."

This disclosure can be used in the safety design of work systems that include robots.

10 Safety sensor, 11, 21 Control unit, 12 Sensor unit, 13, 23 Communication unit, 18 Communication line, 20 PC (design support device), 22 Memory unit, 27 Input unit, 28 Display screen (display unit), 40 Work system, 41 Robot stand, 43 Conveyor device, 43a Roller conveyor, 43b End table, 45 Placement stand, 45a Placement area, 47 Pillar, 50 Robot, 52 Robot arm, 5 4 End effector, 70 Safety design support screen, 71 Model display area, 72 Sensor placement button, 73 Movable/entry area display button, 74 Parameter setting button, 75 Hazard display button, 76 Save button, 77 Output button, 78 Exit button, 79 Pointer, A Detection area, A1 First detection area, A2 Second detection area, D, D1, D2 Hazard, M Operator, P Item, Pa Knob.

Claims (10)

A design support device for supporting a safety design of a work system including a robot, comprising:
a model display processing unit that displays a three-dimensional model of the robot and surrounding objects arranged in a virtual space on a predetermined display screen;
a sensor display processing unit that displays, within the three-dimensional model, safety sensors that monitor the periphery of the robot so as to be arranged at positions and in orientations based on arrangement instructions from a designer;
an area display processing unit that displays, within the three-dimensional model, a detection area of the safety sensor disposed within the three-dimensional model;
A design support device comprising: the area display processing unit displays the detection area so as to be a detection range based on setting information including at least one of an arrangement instruction by a designer and a detection distance, a detection angle, and a non-detection area set in the safety sensor.
The design support device according to claim 1 . the detection area includes a plurality of areas divided so that the robot takes different actions when an object is detected by the safety sensor;
the region display processing unit displays the detection region so that the plurality of regions can be distinguished.
The design support device according to claim 1 or 2. the area display processing unit is capable of displaying a movable area of the robot based on the position information and the operation information of the robot, together with the detection area of the safety sensor, within the three-dimensional model.
The design support device according to claim 1 or 2. The safety sensor is configured to be capable of communicating with the safety sensor via wire or wirelessly,
an output unit that outputs setting information of the detection area displayed by the area display processing unit to the connected safety sensor based on an output instruction from a designer;
The design support device according to claim 1 or 2, comprising: an area setting unit that sets, within the three-dimensional model, a movable area of the robot and an entry area into which at least a part of a body of a worker can enter;
a hazard display processing unit that determines whether or not there is a hazard within an overlapping area between the movable area and the entry area, and displays the hazard within the three-dimensional model when it is determined that there is a hazard;
The design support device according to claim 1 . A design support device for supporting a safety design of a work system including a robot, comprising:
a model display processing unit that displays a three-dimensional model of the robot and surrounding objects arranged in a virtual space on a predetermined display screen;
an area setting unit that sets, within the three-dimensional model, a movable area of the robot and an entry area into which at least a part of a body of a worker can enter;
a hazard display processing unit that determines whether or not there is a hazard within an overlapping area between the movable area and the entry area, and displays the hazard within the three-dimensional model when it is determined that there is a hazard;
A design support device comprising: the hazard display processing unit extracts, from within the overlapping area, a location where a part of the worker's body may come into contact with the robot or may be pinched by the robot, and determines whether or not the location is the hazard based on at least one of a shape, a material, a size, and an operating speed of the location.
The design support device according to claim 6 or 7. A design support method for supporting a safety design of a work system including a robot, comprising:
(a) displaying a three-dimensional model of the robot and surrounding objects arranged in a virtual space on a predetermined display screen;
(b) displaying, within the three-dimensional model, safety sensors that monitor the periphery of the robot, at positions and orientations based on placement instructions from a designer;
(c) displaying, within the three-dimensional model, detection regions of the safety sensors disposed within the three-dimensional model;
A design support method including: A design support method for supporting a safety design of a work system including a robot, comprising:
(a) displaying a three-dimensional model of the robot and surrounding objects arranged in a virtual space on a predetermined display screen;
(b) setting, within the three-dimensional model, a movable area of the robot and an entry area into which at least a part of a body of a worker can enter;
(c) determining whether or not there is a hazard within an overlapping area between the movable area and the entry area, and displaying the hazard within the three-dimensional model when it is determined that the hazard exists;
A design support method including:

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