JP5481105B2 - Cutting device - Google Patents

Description

  The present invention recognizes the shape and dimensions of a material to be cut by processing an image obtained by photographing a material to be cut placed in a cuttable area with a CCD camera, and assigns a figure to be cut to the recognized material to be cut. The present invention relates to a cutting apparatus.

  A cutting torch such as a gas cutting torch, a plasma cutting torch, or a laser cutting torch is selectively mounted on a numerically controlled cutting machine, and it can be cut from materials to be cut such as steel plates, stainless steel plates, non-ferrous metal plates such as aluminum and brass plates. Cutting a dimensional figure is performed.

  For example, a case will be described in which a preset figure is cut from a steel plate using a numerical control (NC) type cutting machine equipped with a plasma cutting torch. A so-called nesting is performed on a steel plate having a specific material, thickness, width and length, and a figure to be cut from the steel plate is assigned to the steel plate, and the nested information is converted into NC information. The nested steel sheet is carried into a cuttable area of the cutting machine, and NC information based on the nesting is input to the cutting machine. Thereafter, when the operation of the cutting machine is started, the cutting machine cuts the steel sheet based on the NC information in accordance with a preset program. In this case, it is possible to cut a large number of figures from one steel plate, and it is possible to perform cutting with less waste.

  On the other hand, when a member having a large size such as a hull member is cut, the steel plate has a special size capable of cutting the target member. For this reason, it is common not to assign other figures to the steel sheet assigned to the target member. In this case, scrap having a relatively large area is generated. Such scraps are often so-called deformed materials that are not limited in shape.

  As described in Patent Document 1, as a cutting device for cutting a deformed material, an imaging device is provided separately from the cutting machine, the deformed material is imaged by a CCD camera, and an image obtained by the image capturing device is obtained. There is a device that creates data to which a figure to be cut is assigned and performs cutting by a cutting torch of a cutting machine based on the data.

  In the technique of the above-mentioned patent document 1, since the image pickup device and the cutting machine are configured as separate bodies, the apparatus becomes large. For this reason, the technique described in Patent Document 2 has also been proposed for the purpose of reducing the size of the apparatus. In the technique of Patent Document 2, since the cutting torch and the camera are provided on the transverse carriage, the cutting torch and the means for moving the camera are integrally configured. For this reason, size reduction of an apparatus can be achieved.

Japanese Patent No. 2548648 JP 2003-251464 A

  However, in the techniques disclosed in Patent Documents 1 and 2, since the cutable area, which is the movable area of the cutting torch, cannot be shot at once by the CCD camera, a process of combining the shot images in several degrees is performed. As a result, there is a problem that the image processing becomes complicated. In recent CCD cameras, an area that can be photographed at a time is widened by using an ultra-wide-angle lens. For this reason, by using such a CCD camera, it has become possible to photograph a severable region at a time.

  However, when the cuttable area is photographed using the CCD camera, there are problems of lens aberration and it is difficult to set the visual axis of the CCD camera perpendicular to the cuttable area. In addition, since it cannot be guaranteed that the area that can be cut has the same brightness throughout the entire area, brightness and darkness appear in the image obtained by photographing the area that can be cut, and the material to be cut is clearly recognized. There is a possibility that a part to be obtained and a part to be clearly recognized are generated.

  In addition, it is impossible to recognize the material and thickness of the material to be cut arranged in the cuttable region from an image taken by the CCD camera. For this reason, such information is generally obtained each time by contacting workers or actually measuring the material to be cut, which should be solved to improve workability. ing.

  An object of the present invention is to assign a figure to be cut from the material to be cut after photographing the cutable region with a CCD camera and substantially accurately recognize the shape and size of the material to be cut arranged in the cuttable region. It is providing the cutting device comprised in this way.

In order to solve the above problems, a cutting device according to the present invention includes a cutting torch for cutting a material to be cut arranged in a cuttable area, a carriage for moving the cutting torch into the cuttable area, and driving of the carriage A trolley drive control device for controlling the image, a CCD camera disposed above the severable area and photographing the severable area, and processing the image of the severable area photographed by the CCD camera to be disposed in the severable area An image processing device for recognizing the shape of the material to be cut, and an allocation control device for allocating a part to be cut to the material to be cut whose shape has been recognized. A lens aberration correction unit that corrects the generated lens aberration, a tilt correction unit that corrects the tilt of the CCD camera in the vertical direction with respect to the cuttable region, and the captured image of the cutable region into a plurality of regions The threshold in a region where separation of the workpiece is not performed by separate and the binarized data of the workpiece from the cutting area by set a threshold value for each of the regions obtained by dividing the binarized data as well as split And a shape recognizing unit that recognizes the shape of the material to be cut based on the binarized data that is sequentially reduced and set .

  In the above-described cutting apparatus, the material to be cut is provided with an information display unit that displays information on the material and thickness of the material to be cut in advance. It is preferable that a material recognition unit for recognizing the material and thickness of the material to be cut is provided.

  In the above-described cutting apparatus, the lens aberration generated in the image obtained by photographing the severable area by the CCD camera disposed above the severable area can be corrected by the lens aberration correction unit, and the inclination of the CCD camera with respect to the severable area Can be corrected by the inclination correction unit. Furthermore, the shape recognition unit divides the photographable cuttable area into a plurality of areas, and sets a threshold value for each divided area to binarize it, so that whether or not the light and dark distribution of the actual cuttable area is related. Therefore, it is possible to reliably recognize the shape of the material to be cut arranged in the cuttable region.

  In addition, by providing an information display unit that displays information on the material and thickness of the material to be cut, information necessary for cutting can be recognized by processing an image obtained by photographing the information display unit. For this reason, a cutting | disconnection can be performed based on reliable information.

It is the whole cutting device schematic. It is a block diagram which illustrates roughly the control system of a cutting device. It is a figure explaining the procedure at the time of processing the image image | photographed with the CCD camera. It is explanatory drawing of nesting.

  First, the configuration of the cutting apparatus A according to the present embodiment will be described with reference to FIG.

  The cutting device A captures the cuttable area B by the CCD camera 1, processes this image by the image processing device 10, recognizes the shape of the material S to be cut arranged in the cuttable area B, and assigns the control device The parts to be cut are assigned to the material to be cut S by 20 to form cutting data, and the cutting data is transmitted to the carriage drive control device 30 to control the driving of the carriage 40 and to control the operation of the cutting torch 2. Thus, the material to be cut S is cut.

  First, the configuration of the carriage 40 will be briefly described. The trolley | bogie 40 should just be able to move the cutting torch 2 in the area | region B which can be cut | disconnected, and does not limit a structure. That is, the structure of the carriage 40 is set according to the size of the cuttable area B. Examples of such a carriage 40 include a structure in which a cutting torch is mounted on a cantilever boom configured to be movable along a pair of rails laid in parallel, a robot having a multi-joint arm, and the like.

  In the present embodiment, the carriage 40 includes a frame 41 that travels while being placed on a pair of rails 45 disposed on both sides of the cuttable region B in the width direction. The frame 41 is configured in a gate shape including a saddle 41 a and a garter 41 b arranged in a direction orthogonal to the rail 45. The garter 41b is provided with a traverse carriage 42 that traverses along the garter 41b. The cutting torch 2 is mounted on the transverse carriage 42.

  A control panel 50 is mounted on the frame 41 of the carriage 40, and an image processing apparatus 10, an assignment control apparatus 20, and a carriage drive control apparatus 30 described later are incorporated in the control board 50.

  A traveling motor 43 a is attached to the saddle 41 a constituting the frame 41, and a transverse motor 43 b and a lifting motor 43 c are attached to the transverse carriage 42. The travel motor 43a travels the frame 41 along the rail 45 in a desired direction at a desired speed. The traverse motor 43b traverses the traverse carriage 42 along the garter 41b in a desired direction at a desired speed. Further, the elevating motor 43c raises or lowers the cutting torch 2.

  In the carriage 40 configured as described above, the rotation direction and the rotation speed of the travel motor 43a and the traverse motor 43b can be independently controlled by the carriage drive control device 30 including a numerical control (NC) device. By controlling the rotation of the motors 43a and 43b, the traveling direction and traveling speed of the frame 41, the transverse direction and transverse speed of the transverse carriage 42 can be controlled, and the moving direction and speed of the cutting torch 2 can be controlled. It is configured. Therefore, the cutting torch 2 can be moved in a desired direction at a desired speed.

  The configuration of the cutting torch 2 is not limited, and a cutting torch such as a gas cutting torch, a plasma cutting torch, or a laser cutting torch is selectively used according to conditions such as the material and thickness of the material S to be cut. Is possible. The equipment necessary for operating the selected cutting torch (for example, gas supply equipment, power supply equipment, laser oscillation equipment, etc., not shown) is mounted on the frame 41 or installed on the floor of the factory. Yes.

  In the present embodiment, the material to be cut S is a steel plate, and a gas cutting torch is used as the cutting torch 2. Then, after preheating the material to be cut S by a flame in which oxygen and fuel supplied from an oxygen gas supply source and a fuel gas supply source are mixed and burnt, the target component is injected by cutting oxygen and cut. Is configured to get.

  The shape of the material S to be cut by the cutting torch 2 is not limited, and is any of a rectangular steel plate having a preset standard and a deformed steel plate that does not have a shape such as a scrap material. There may be. In this embodiment, the material to be cut S is composed of a substantially trapezoidal deformed material.

  When the workpiece S is cut, the thickness is an important condition for setting the cutting speed. However, the thickness is not displayed on the material to be cut S, and it is general that the material to be cut S is directly measured and recognized when cutting is performed. For this reason, in addition to the work of recognizing the shape of the material to be cut S arranged in the cuttable region B and assigning parts to be cut, the thickness of the material to be cut S is measured and input to the cart drive control device 30. It is necessary to do work to do.

  In the present embodiment, an information display unit 3 that displays information such as the thickness and material of the material to be cut S is provided on the surface of the material to be cut S. The information display unit 3 may display information as numbers and characters, or may display it as code information including a barcode. In any case, any material can be used as long as it can recognize the plate thickness and material from an image obtained by photographing the cuttable region B where the material to be cut S is arranged.

  The cuttable area B is set corresponding to the range in which the cutting torch 2 mounted on the transverse carriage 42 of the carriage 40 can move. That is, the dimension of the cuttable area B is set in accordance with a preset specification, and the moving range of the cutting torch 2 is set so as to satisfy the set cuttable area B.

  The structure for supporting the material to be cut S arranged in the severable region B is not limited. For example, the cutting surface plate arranged with a large number of flat bars standing up, the cutting surface plate arranged with a large number of rod-like bodies standing up, or the cutable region B with the material to be cut S placed thereon It is possible to selectively employ a pallet that enters and is discharged after the cutting of the workpiece S is completed.

  The size of the cuttable area B is not limited, but is a range that can be photographed by the CCD camera 1 by one photographing. Therefore, the size of the cuttable area B changes in accordance with the performance of the CCD camera 1 and the distance from the cuttable area B of the CCD camera 1. In this embodiment, the dimensions of the cuttable region are set to 6500 mm in the X direction along the laying direction of the rail 45 and 2500 mm in the Y direction crossing the rail 45. In particular, when the severable area B is imaged by the CCD camera 1, the rail 45 is dimensioned so that the trolley 40 can be retracted to the length in the X direction of the severable area B in order to retract the trolley 40 from the severable area B. It is laid in the length which added.

  Although the specification of the CCD camera 1 is not limited, it is preferable that an ultra-wide-angle lens is provided so that a wide cuttable area B can be photographed by one photographing. In this embodiment, a super-wide-angle lens having a focal length of 2.8 mm and a CCD camera 1 having about 1 million pixels are installed approximately 3000 mm above the cuttable area B, so that the cuttable area B is photographed at once. ing.

  Image data photographed by the CCD camera 1 is transmitted to an image processing device 10 constituted by a computer, and the lens aberration and the tilt of the CCD camera 1 are corrected by the image processing device 10 as will be described later. The shape of S, the thickness of the material to be cut S, and the material are recognized. The image processing apparatus 10 includes a lens aberration correction unit 11, an inclination correction unit 12, a shape recognition unit 13, a material recognition unit 14, and a program storage unit that stores processing programs in the units 11 to 14. And a temporary storage unit for temporarily storing data processed by the units 11 to 14.

  As described above, since the CCD camera 1 includes the super-wide-angle lens, the captured image is distorted due to lens aberration (see the chain line 15 in FIG. 3). The distortion 15 due to the lens aberration is corrected by the lens aberration correction unit 11 constituting the image processing apparatus 10.

  Further, the visual axis 1a of the CCD camera 1 needs to be arranged perpendicular to the cuttable area B. However, it is difficult to arrange and maintain the visual axis 1a perpendicular to the cuttable region B. For this reason, the image taken by the CCD camera 1 reflects the inclination of the visual axis 1a with respect to the severable region B, and the image is distorted as indicated by a two-dot chain line 16 in FIG. The distortion 16 due to the tilt of the CCD camera 1 is corrected by the tilt correction unit 12 constituting the image processing apparatus 10.

  Further, since the severable area B is installed in the factory, it is affected by the brightness of the surroundings, and a difference in brightness often occurs partially. Accordingly, in the image obtained by photographing the cutable region B where the material to be cut S is arranged, a portion where the cut material S and the cutable region B can be clearly separated and recognized, and a portion where the separation between the two is not clear Will occur. For this reason, the shape recognition unit 13 constituting the image processing apparatus 10 divides an image photographed by the CCD camera 1 into a plurality of regions 17a to 17d shown in FIG. 3, and has different threshold values for the respective regions 17a to 17d. By binarizing, the exact shape of the workpiece S is recognized. In addition, the number of division | segmentation of the area | region B which can be cut | disconnected is not limited, Of course, it may divide into 4 like a present Example, and may divide | segment into 6 divisions or more.

  The image processing apparatus 10 is further provided with a material recognition unit 14. When the shape of the material to be cut S is recognized from an image taken by the CCD camera 1, the information display unit 3 provided on the material to be cut S is displayed. The thickness, material, etc. of the material to be cut S are recognized from the displayed information.

  Next, each part 11-14 which comprises the said image processing apparatus 10 is demonstrated.

  First, a lens aberration correction method by the lens aberration correction unit 11 will be described. Many methods have been proposed for correcting lens aberration, and any method can be employed. In this embodiment, the ultra-wide-angle lens attached to the CCD camera 1 is calibrated, lens aberration correction parameters are set, and lens aberrations are corrected using the lens aberration correction parameters.

  That is, the lens aberration correction parameter investigated in advance is stored in the lens aberration correction unit 11, and the captured image data is corrected by the lens aberration correction parameter, so that the portion corresponding to the distortion from the image in which the distortion due to the lens aberration has occurred. Can be corrected.

  Next, a method for correcting the tilt of the visual axis 1a of the CCD camera 1 by the tilt correction unit 12 will be described. First, a rectangular plate whose dimensions are accurately measured is placed in the cuttable area B and photographed by the CCD camera 1. A conversion count is obtained by comparing the rectangular dimension reflected in the image data with the actual rectangular dimension. Then, the inclination of the visual axis 1a of the CCD camera 1 is corrected by correcting the image data obtained by photographing the material to be cut S and having the lens aberration corrected by the lens aberration correction unit 11 with the conversion coefficient. Is possible.

  In other words, the conversion coefficient obtained in advance is stored in the inclination correction unit 12, and the image data photographed by the CCD camera 1 and the lens aberration corrected by the lens aberration correction unit 11 is converted by the inclination correction unit 12. It is possible to correct the inclination of the visual axis 1a of the CCD camera 1 with respect to the cuttable area B.

  Next, a method of recognizing the shape of the material to be cut S by dividing the cuttable region B into a plurality of regions 17a to 17d will be described. The shape recognition unit 13 uses an image photographed by the CCD camera 1 and has been subjected to the correction of distortion due to lens aberration and the correction of distortion due to the tilt of the visual axis 1a of the CCD camera 1, and the cutable area B Is divided into a plurality of regions (four regions 17a to 17d in this embodiment).

  A threshold value is set for each of the divided areas 17a to 17d and binarized to separate the material to be cut S and the cuttable area B from each other. The partial shape of the material to be cut S is recognized from the separated data for the region where the material to be cut S and the cutable region B are separated by the data binarized with the threshold value initially set. Is possible. In the region where the material to be cut S and the severable region were not separated at the first set threshold value, the first set threshold value was lowered, the second threshold value was set, binarized, and binarized The material to be cut S and the cuttable region B are separated based on the data. Then, in the region where the material to be cut S and the cutable region B are not separated by the second threshold value, the third threshold value is further set and binarized. The possible area B is separated. In this way, by setting threshold values that are sequentially reduced and binarizing, it is possible to separate the material to be cut S and the cuttable area B even when the change in brightness in the captured image is small. is there.

  As described above, it is possible to create a binarized image for each of the regions 17a to 17d, perform contour calculation from the created image, and recognize the shape and dimensions of the material S to be cut. Then, contour line data is created from the recognized shape and size of the workpiece S.

  After recognizing the shape of the material to be cut S, the material recognition unit 14 recognizes material information such as the thickness and material of the material to be cut displayed on the information display unit 3 from the image data. The material information is recognized in accordance with the display format of the information display unit 3. For example, when the information display unit 3 is displayed by numbers or characters, the character recognition is performed simultaneously with the recognition of the shape of the material S to be cut. Do that. When the information display unit 3 displays a code including a barcode, the information display unit 3 recognizes the code.

  Information necessary for the operation of the image processing apparatus 10 is input from input means 51 such as a keyboard. Further, an image photographed by the CCD camera 1 and an image in the process in each of the units 11 to 14 are displayed on an output means 52 such as a display. The input means 51 and the output means 52 may be dedicated to the image processing apparatus 10, but are preferably common to the assignment control apparatus 20 and the cart drive control apparatus 30.

  The contour line data including the shape and size of the material to be cut S recognized as described above, and the material data including the plate thickness and material of the material to be cut S are stored in the temporary storage unit of the image processing apparatus 10. Then, the contour line data is sent to the assignment control device 20, and the assignment control device 20 assigns parts to be cut from the workpiece S. Further, the material data is sent to the allocation control device 20 and the cart drive control device 40, used for searching the component data and creating NC data in the allocation control device 20, and the cutting speed in the cart drive control device 30. It is used as an element when setting.

  The allocation control device 20 is configured by a computer, and stores a program storage unit that stores a program for allocating parts to the workpiece S whose shape and dimensions are recognized, and the shape, dimensions, and plates of the parts requested by the ordering department. A storage unit that stores component data including information such as thickness, material, and quantity, and a calculation unit are included.

  Information such as the shape, dimensions, plate thickness, material, quantity, etc. of parts requested in advance from the ordering department, which is a department different from the cutting department, is input to the allocation control device 20 from the input means 51 and stored in the storage unit as part data. It is remembered.

  The allocating unit 21 receives the contour line data and material data of the material to be cut S recognized by the image processing apparatus 10, and from the component data stored in the storage unit, the plate thickness and material that match the material data Read the part consisting of Next, according to the program for allocating the components stored in the program storage unit, the components 25 to 27 corresponding to the read component data are allocated inside the contour line of the workpiece S as shown in FIG.

  The allocation status of the parts 25 to 27 with respect to the workpiece S is output to the output means 52. At this time, it is possible for the operator to perform adjustment by operating the input unit 51 while examining the display contents output to the output unit 52. In this way, the adjustment by the operator is performed, and the assignment of the parts 25 to 27 to the workpiece S is completed.

  When the assignment of the parts 25 to 27 to the material to be cut S is completed, the data consisting of the contour line data of the material to be cut S and the assigned part data is sent to the NC data creating unit 22 and the cart drive control device comprising the NC device. NC data that is 30 languages is created. The NC data created by the NC data creation unit 22 is sent to the carriage drive control device 30 to control the operation of the carriage 40 and the cutting torch 2 mounted on the carriage 40.

  Next, an operation procedure of the cutting apparatus A configured as described above will be described. First, the carriage 40 is retracted from the cuttable area B, and the material to be cut S is arranged in the cuttable area B. Further, the parts data requested from the ordering department is stored in advance in the allocation control device 20. In this state, the CCD camera 1 captures the cuttable area B and sends the captured image to the image processing apparatus 10.

  In the image processing apparatus 10, the lens aberration correction unit 11 corrects distortion due to lens aberration from the image taken by the CCD camera 1, and the tilt correction unit 12 corrects distortion due to the tilt of the visual axis 1a of the CCD camera 1 from the corrected image. to correct. Then, the shape recognition unit 13 divides the image after correcting the distortion due to the lens aberration and the distortion due to the inclination of the visual axis 1a into a plurality of regions 17a to 17d and clearly recognizes the contour line in each region. The contour data is formed by recognizing the shape of the workpiece S, and the contour data is stored in the storage unit.

  When recognizing the shape of the material to be cut S, the material recognition unit 14 recognizes the thickness and material of the material to be cut S from the information display unit 3 provided on the material to be cut S, and forms material data. The material data is stored in the storage unit. By storing the contour line data and material data of the material to be cut S in the storage unit of the image processing apparatus 10 in this way, the shape and dimensions of the material to be cut S currently arranged in the cuttable region B, the plate Thickness and material will be recognized.

  Next, the assignment control device 20 reads out the contour line data and material data of the material to be cut S from the image processing device 10, and reads out part data that matches the material data of the material to be cut S from the pre-stored department. . Then, the shape, size, and number of the read component data are assigned in combination with the contour line data of the workpiece S. When the assignment of parts to the material to be cut S is completed, NC data is created from these data and sent to the cart drive control device 30.

  After the NC data is sent to the cart drive control device 30, when the operator operates the cart drive control device 30 to start cutting, the traveling motor 43 a and the traversing motor 43 b are in response to a command from the cart drive control device 30. Is operated, and the cutting torch 2 is moved to the cutting start position for the workpiece S.

  After the cutting torch 2 reaches the cutting start position for the material S to be cut, the cutting torch 2 is stopped, and fuel gas and oxygen are supplied and ignited to preheat the material S to be cut. After a predetermined preheating time has elapsed, cutting oxygen is supplied, and the cutting of the material S to be cut by the cutting torch 2 starts. At the same time, the motors 43a and 43b are driven to move the cutting torch 2 along the shapes of the parts 25 to 27 assigned to the material S to be cut.

  When the parts 25 to 27 allocated to the workpiece S are cut, the supply of oxygen and fuel gas supplied to the cutting torch is stopped, and a series of cutting operations is completed. Thereafter, the carriage 40 is retracted from the cuttable area B, and the cut material S and the parts 25 to 27 that have been cut are discharged from the cuttable area B.

  The cutting apparatus A of the present invention can be used not only for cutting a material to be cut made of a deformed material such as scrap, but also for cutting a material having a standard size.

A cutting device B cuttable area S material to be cut 1 CCD camera 2 cutting torch 3 information display unit 10 image processing device 11 lens aberration correction unit 12 tilt correction unit 13 shape recognition unit 14 material recognition unit 1a visual axis 15 distortion 16 distortion 17a -17d area 20 allocation control device 21 allocation unit 22 NC data creation unit 25-27 parts 30 cart drive control device 40 cart 41 frame 41a saddle 41b garter 42 traverse carriage 43a travel motor 43b traverse motor 43c elevating motor 45 rail 50 control panel 51 Input means 52 Output means

Claims (2)

A cutting torch for cutting a material to be cut arranged in a cuttable region;
A carriage for moving the cutting torch within a cuttable region;
A cart drive control device for controlling the drive of the cart;
A CCD camera arranged above the severable area and photographing the severable area;
An image processing device that processes the image of the cuttable area photographed by the CCD camera and recognizes the shape of the material to be cut arranged in the cuttable area;
An allocation control device for allocating a part to be cut to a workpiece whose shape is recognized;
Have
The image processing apparatus includes a lens aberration correction unit that corrects lens aberration generated in a captured image, a tilt correction unit that corrects a tilt in a vertical direction of the CCD camera with respect to the cuttable region, and an image of the shot cuttable region. The material to be cut is separated from the cuttable region by binarized data by dividing the region into a plurality of regions and setting a threshold value for each divided region, and the material to be cut is not separated by the binarized data. A cutting apparatus comprising: a shape recognition unit that recognizes a shape of a material to be cut based on binarized data set by sequentially reducing a threshold value in an area .   The material to be cut is provided with an information display unit that displays information on the material and plate thickness of the material to be cut in advance, and the image processing apparatus uses the image of the information display unit taken and the material and plate of the material to be cut. The cutting apparatus according to claim 1, wherein a material recognition unit for recognizing the thickness is provided.