Abstract: An image processing method for improving the reliability of an industrial visual sensor, in which image data picked up by a camera of the visual sensor are marked with flags such as data for specifying the image data or a detected value for the image data, program name, calibration data, correction data, etc., and are stored in an auxiliary storage device. After a production line is stopped, the image data having so far been stored in the auxiliary storage device are successively invoked to a frame memory of the visual sensor in accordance with the flags. An image processing program is reproductively executed for the invoked image data. Then, established teaching data are checked for reliability, and the cause of a failure in image data detection, if any, is examined, with reference to the information displayed on a monitor screen.

Abstract: A method of controlling a robot to perform a weaving action and a tracking action using a non-contact sensor. When a weaving start command with a condition of a cycle Tw is issued, a laser sensor starts scanning in a cycle Tw/2n in synchronism with the start of weaving action, and outputs sensor data for every scanning time to be stored in a memory. After starting the weaving action, the robot performs a weaving action with a welding line as a reference path, until the tool reaches the weaving extreme (Sm, Sn+m, S2n+m, . . . ) or the termination of the weaving according to the weaving condition. Since a timed relationship between the weaving action and the scanning action of the laser sensor is known, the robot position corresponding to detection data can be calculated, based on which it is possible to successively determine a target position of the robot movement by adding a weaving amount for each detection point.

Abstract: A robot controlling method and apparatus using a laser sensor in which an optimum moving path is realized even if the accuracy of positioning workpieces is low. While a laser sensor is operated, a robot is started to move toward a taught position corresponding to the start position of a welding line. When the workpieces W1 and W2 are detected, a three-dimensional position of the points Q1-Q4 are calculated. The equations of a straight line Q1Q2 and a straight line Q3Q4 are obtained from position data of points Q1-Q4, and a corner position Q0 is calculated as a crossing point of these two straight lines. Then, access is made to a register, which is designated by an address designation counter value i, to read position shift data. When i=1, .DELTA.x=.DELTA.y=.DELTA. is read and a position shifted from the position Q0 by .DELTA. respectively along the straight lines Q1Q2 and Q3Q4 is calculated as a target position to which the robot movement is performed.

Abstract: A robot is moved to a laser sensor detection angle adjustment position, and scanning with a laser beam is started. As this is done, a reading-scanning operation of a CCD light detector of a laser sensor is executed repeatedly, and cell numbers i for maximum detection outputs and their output values .beta.i are stored. When the laser beam scanning is finished, the individual output values .beta.i are compared with a reference value .alpha.. If all the values .beta.i are not greater than the reference value .alpha., then the robot attitude is changed by a small angle, and repetition of laser beam scanning, reading-scanning of the CCD detector, storing of cell numbers i for the great detection output and their output values .beta.i and comparison between the values .beta.i and the reference value .alpha. are repeated. An attitude .phi. for the point of time when the reference value .alpha. is exceeded by all the values .beta.

Abstract: A robot supports a welding torch for use in arc welding of a cylindrical welding object. The welding object is rotated about an axis and is controlled by a robot controller. The robot is operated to track the welding torch along a calculated welding line to continuously position the welding torch along the welding line. A reference circle is formed by rotation of one point on the welding object. A coordinate system is set with a center corresponding to the center of the reference circle. A laser sensor detects a point on the welding line, and the detected point is stored by using a distance r from a center O of the work coordinate system and a z-coordinate value z. As the cylindrical welding object is rotated by an angle .theta. corresponding to an interval between the position detected by the laser sensor and a calculated second position, the welding torch is moved to a position to coincide with the second position.

Abstract: A visual sensor coordinate system setting jig comprising a jig including a plurality of feature points arranged at known intervals in an array state corresponding to a visual sensor coordinate system, and a visual sensor to receive an image of the plurality of feature points of the jig, at least three of the plurality of feature points each having a distinguishing appearance which the visual sensor recognizes to discriminate the at least three feature points from the other of the plurality of feature points, the at least three feature points representing an origin and coordinate axes of the visual sensor coordinate system, and the visual sensor to identify the origin and the coordinate axes of the visual sensor coordinate system based on the array state of the plurality of feature points and the distinguishing appearance of the at least three feature points.

Abstract: A method of controlling a robot attached to a tool. The position of the robot is corrected in real time by detecting a target position on a workpiece by a laser sensor. A laser light emitted from a laser light source of the laser sensor scans a surface of the workpiece toward a direction across an operating line. An initial scanning forms a locus of laser irradiation points and crossing points which intersect the locus with the operating line on the workpiece. Angle .alpha. is defined to be an angle formed between an axis of the tool and the locus on the surface of the workpiece. Angle .beta. is defined to be an angle formed between the operating line (point series line connecting the crossing points obtained by a current and past scanning) and the center axis of the tool. Further, angle .gamma. is defined to be a rotation angle around an axis of the tool on the basis of the operating line. An attitude of the robot is determined by the angles .alpha., .beta. and .gamma..

Abstract: A method for automatically effecting calibration between an image processing apparatus and a control device of an automatic machine. Jig data for calibration and the position of a robot, fitted with a jig which can be photographed by a camera at the time of calibration, are previously given as instructions. In response to a calibration command, the robot, fitted with the jig, moves to a point of instruction, the image processing apparatus photographs the jig and fetches an image after the movement. A calibration process is executed in accordance with data of the photographed image, set jig data, and robot position. When the jig data and the instruction point are first set and given once as instructions, the calibration thereafter can be automatically effected only by mounting the jig on the robot and inputting the calibration command.

Abstract: A robot coordinate system setting method is provided which facilitates the setting of a common coordinate system with respect to each of robots in a robot system or a robot installed in substitution for one of the robots. A coordinate transformation matrix for transforming a provisional coordinate system (X2Y2Z2), which a first robot has recognized by accessing a second jig, into a common coordinate system (X1Y1Z1), which the first robot has recognized by accessing a first jig, is calculated, and using this coordinate transformation matrix, a provisional coordinate system which a second robot has recognized by accessing the second jig is transformed into the common coordinate system which is to be recognized by the second robot, and is set with respect to the second robot.