Workpiece detector, robot system, method for producing to-be-processed material, method for detecting workpiece

Patent metadata

Field	Value
Publication number	US-9283680-B2
Application number	US-201414295261-A
Country	US
Kind code	B2
Filing date	Jun 3, 2014
Priority date	Jun 7, 2013
Publication date	Mar 15, 2016
Grant date	Mar 15, 2016

Abstract

A workpiece detector includes a camera to acquire a two-dimensional image of a search range within which workpieces are disposed. A three-dimensional sensor detects a three-dimensional shape of a three-dimensional detection area. A workpiece extraction section processes the two-dimensional image to extract candidate workpieces. An area setting section sets a three-dimensional detection areas respectively corresponding to the candidate workpieces. A prioritizing section sets an order of priority to the three-dimensional detection areas to give higher priority to one three-dimensional detection area containing more of the candidate workpieces. A sensor control section controls the three-dimensional sensor to detect the three-dimensional shape of each three-dimensional detection area in the order of priority. Every time the three-dimensional shape is detected, a workpiece detection section searches the workpieces based on the detected three-dimensional shape to detect a pickable workpiece.

First claim

What is claimed as new and desired to be secured by Letters Patent of the United States is:

1. A workpiece detector comprising:
a camera configured to acquire a two-dimensional image of a search range within which workpieces are disposed;
a three-dimensional sensor configured to detect a three-dimensional shape of a three-dimensional detection area;
a workpiece extraction section configured to process the two-dimensional image to extract a plurality of candidate workpieces among the workpieces;
an area setting section configured to set a plurality of three-dimensional detection areas respectively corresponding to the plurality of candidate workpieces;
a prioritizing section configured to set an order of priority to the plurality of three-dimensional detection areas based at least in part on a quantity of candidate workpieces present in each of the plurality of three-dimensional detection areas so as to give higher priority to one three-dimensional detection area among the plurality of three-dimensional detection areas such that the one three-dimensional detection area that contains more of the plurality of candidate workpieces is given higher priority;
a sensor control section configured to control the three-dimensional sensor to detect the three-dimensional shape of each of the plurality of three-dimensional detection areas in the order of priority; and
a workpiece detection section configured to, every time the three-dimensional shape is detected, search the workpieces based on the detected three-dimensional shape so as to detect a pickable workpiece among the workpieces.

2. The workpiece detector according to claim 1 , further comprising a transfer mechanism configured to transfer the three-dimensional sensor.

3. A workpiece detector comprising:
a camera configured to acquire a two-dimensional image of a search range within which workpieces are disposed;
a three-dimensional sensor configured to detect a three-dimensional shape of a three-dimensional detection area;
a workpiece extraction section configured to process the two-dimensional image to extract a plurality of candidate workpieces among the workpieces;
an area setting section configured to set a plurality of three-dimensional detection areas respectively corresponding to the plurality of candidate workpieces;
a prioritizing section configured to set an order of priority to the plurality of three-dimensional detection areas so as to give higher priority to one three-dimensional detection area among the plurality of three-dimensional detection areas when the one three-dimensional detection area contains more of the plurality of candidate workpieces;
a sensor control section configured to control the three-dimensional sensor to detect the three-dimensional shape of each of the plurality of three-dimensional detection areas in the order of priority; and
a workpiece detection section configured to, every time the three-dimensional shape is detected, search the workpieces based on the detected three-dimensional shape so as to detect a pickable workpiece among the workpieces,
wherein the prioritizing section is configured to give higher priority to the one three-dimensional detection area when the one three-dimensional detection area has a smaller area overlapping a placement area in which the workpieces are placeable.

4. A workpiece detector comprising:
a camera configured to acquire a two-dimensional image of a search range within which workpieces are disposed;
a three-dimensional sensor configured to detect a three-dimensional shape of a three-dimensional detection area;
a workpiece extraction section configured to process the two-dimensional image to extract a plurality of candidate workpieces among the workpieces;
an area setting section configured to set a plurality of three-dimensional detection areas respectively corresponding to the plurality of candidate workpieces;
a prioritizing section configured to set an order of priority to the plurality of three-dimensional detection areas so as to give higher priority to one three-dimensional detection area among the plurality of three-dimensional detection areas when the one three-dimensional detection area contains more of the plurality of candidate workpieces;
a sensor control section configured to control the three-dimensional sensor to detect the three-dimensional shape of each of the plurality of three-dimensional detection areas in the order of priority; and
a workpiece detection section configured to, every time the three-dimensional shape is detected, search the workpieces based on the detected three-dimensional shape so as to detect a pickable workpiece among the workpieces,
wherein the prioritizing section is configured to give higher priority to the one three-dimensional detection area when the one three-dimensional detection area contains a candidate workpiece with a higher photography magnification in the two-dimensional image.

5. A workpiece detector according to claim 1 , comprising:
a camera configured to acquire a two-dimensional image of a search range within which workpieces are disposed;
a three-dimensional sensor configured to detect a three-dimensional shape of a three-dimensional detection area;
a workpiece extraction section configured to process the two-dimensional image to extract a plurality of candidate workpieces among the workpieces;
an area setting section configured to set a plurality of three-dimensional detection areas respectively corresponding to the plurality of candidate workpieces;
a prioritizing section configured to set an order of priority to the plurality of three-dimensional detection areas so as to give higher priority to one three-dimensional detection area among the plurality of three-dimensional detection areas when the one three-dimensional detection area contains more of the plurality of candidate workpieces;
a sensor control section configured to control the three-dimensional sensor to detect the three-dimensional shape of each of the plurality of three-dimensional detection areas in the order of priority; and
a workpiece detection section configured to, every time the three-dimensional shape is detected, search the workpieces based on the detected three-dimensional shape so as to detect a pickable workpiece among the workpieces,
wherein the prioritizing section is configured to give lower priority to another three-dimensional detection area of lower priority than the higher priority of the one three-dimensional detection area when the another three-dimensional detection area has a larger area overlapping the one three-dimensional detection area of higher priority.

6. A robot system comprising:
the workpiece detector according to claim 1 ;
a robot comprising a holding mechanism configured to hold a workpiece among the workpieces; and
a robot controller configured to control the robot to make the holding mechanism hold and transfer a workpiece among the workpieces detected by the workpiece detector.

7. A robot system comprising:
the workpiece detector according to claim 2 ;
a robot comprising a holding mechanism configured to hold a workpiece among the workpieces; and
a robot controller configured to control the robot to make the holding mechanism hold and transfer a workpiece among the workpieces detected by the workpiece detector,
wherein the three-dimensional sensor is mounted to the robot, and
wherein the workpiece detector is configured to use the robot and the robot controller as the transfer mechanism.

8. A method for producing a to-be-processed material comprising:
acquiring, using a camera, a two-dimensional image of a search range within which workpieces are disposed;
processing the two-dimensional image to extract a plurality of candidate wor

Assignees

• Yaskawa Denki Seisakusho Kk

Inventors

• Yasuda Yuya
• Aoyama Issei
• Irie Toshimitsu

Classifications

• G05B2219/40053

  Pick 3-D object from pile of objects · CPC title

• G06K9/00664

  Physics · mapped topic

• B25J9/1697 Primary

  Vision controlled systems · CPC title

• G06K9/00201

  Physics · mapped topic

• H04N7/183

  for receiving images from a single remote source · CPC title