Workpiece detector, robot system, method for producing to-be-processed material, method for detecting workpiece
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.
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 workpieces among the workpieces;
setting a plurality of three-dimensional detection areas respectively corresponding to the plurality of candidate workpieces;
setting 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;
detecting, using a three-dimensional sensor, a three-dimensional shape of each of the plurality of three-dimensional detection areas in the order of priority;
every time the three-dimensional shape is detected, searching the workpieces based on the detected three-dimensional shape so as to detect a pickable workpiece among the workpieces;
holding the detected workpiece using a holding mechanism of a robot; and
transferring, using the robot, the workpiece held by the holding mechanism to a next process.
9. A method for detecting a workpiece 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 workpieces among the workpieces;
setting a plurality of three-dimensional detection areas respectively corresponding to the plurality of candidate workpieces;
setting 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;
detecting, using a three-dimensional sensor, a three-dimensional shape of each of the plurality of three-dimensional detection areas in the order of priority; and
every time the three-dimensional shape is detected, searching the workpieces based on the detected three-dimensional shape so as to detect a pickable workpiece among the workpieces.
10. The workpiece detector according to claim 2 , 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.
11. The workpiece detector according to claim 2 , 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.
12. The workpiece detector according to claim 3 , 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.
13. The workpiece detector according to claim 10 , 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.
14. The workpiece detector according to claim 2 , 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.
15. The workpiece detector according to claim 3 , 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.
16. The workpiece detector according to claim 4 , 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.
17. The workpiece detector according to claim 10 , 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.
18. The workpiece detector according to claim 11 , 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.
19. The workpiece detector according to claim 12 , 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.
20. The workpiece detector according to claim 13 , 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.