Welding machine and control method therefor

1. A welding machine comprising:

a camera that photographs a master product to obtain a photographed master image and that photographs a workpiece to obtain a photographed workpiece image;

an operation unit by which an operator indicates coordinates on the photographed master image;

a computer that

performs operations using the photographed master image, comprising:

receiving first coordinates on the photographed master image, the first coordinates being indicated on a master constant surface by the operation unit, the master constant surface being a region of the master product determined to lack a positional deviation with respect to a master welding point on the master product, the master welding point being a welding point set by a processing program for welding the master product;

extracting a master edge image of the master product from the photographed master image;

acquiring a master constant surface region of the master constant surface including the first coordinates; and

acquiring a master constant edge image based on the master edge image and the master constant surface region, the master constant edge image including a first edge image of the master constant surface region; and

performs operations using the photographed workpiece image, comprising:

extracting a workpiece edge image of the workpiece from the photographed workpiece image;

acquiring a workpiece constant surface region including second coordinates of a position on the photographed workpiece image, the second coordinates being obtained based on the first coordinates;

acquiring a workpiece constant edge image based on the workpiece edge image and the workpiece constant surface region, the workpiece constant edge image including a second edge image of the workpiece constant surface region;

performing pattern-matching between the master constant edge image and the workpiece constant edge image so as to match the first edge image and the second edge image to acquire a first deviation amount between the master constant edge image and the workpiece constant edge image as a correction amount for a workpiece welding point, wherein the workpiece welding point is set by the processing program and is a point at which the workpiece is welded; and

correcting the workpiece welding point by the correction amount to generate a corrected processing program for welding the workpiece; and

a welding robot that welds the workpiece based on the corrected processing program.

2. The welding machine according to claim 1 , wherein the computer further

performs operations using the photographed master image, comprising:

estimating the master constant surface region based on the master edge image and the first coordinates to acquire the master constant surface region; and

acquiring the first edge image in the master constant surface region; and

performs operations using the photographed workpiece image, comprising:

estimating the workpiece constant surface region based on the workpiece edge image and the second coordinates to acquire the workpiece constant surface region; and

acquiring the second edge image in the workpiece constant surface region.

3. The welding machine according to claim 2 , wherein the computer further

performs operations using the photographed master image and the photographed workpiece image, comprising:

aligning the master edge image and the workpiece edge image with each other to acquire a second deviation amount between the master edge image and the workpiece edge image; and

acquiring the second coordinates by shifting the first coordinates by the second deviation amount.

4. A control method for a welding machine, the control method comprising:

defining a product as a master, which is taken as a reference among a plurality of products;

defining another product among the plurality of products other than the master as a workpiece;

acquiring a photographed master image by photographing, with a camera, a region including a master welding point and an edge on the master, the master welding point being a welding point set by a processing program for welding the master;

receiving first coordinates of a position on the photographed master image, the first coordinates being indicated on a master constant surface by an operation unit, the master constant surface being a region of the master determined to lack a positional deviation with respect to the master welding point;

extracting a master edge image of the master from the photographed master image;

acquiring a master constant surface region of the master constant surface including the first coordinates;

acquiring a master constant edge image based on the master edge image and the master constant surface region, the master constant edge image including a first edge image of the master constant surface region;

acquiring a photographed workpiece image by photographing, with the camera, a region including a workpiece welding point and an edge on the workpiece, the workpiece welding point being set by the processing program for welding the workpiece together;

extracting a workpiece edge image of the workpiece from the photographed workpiece image;

acquiring a workpiece constant surface region including second coordinates of a position on the photographed workpiece image, the second coordinates being obtained based on the first coordinates;

acquiring a workpiece constant edge image based on the workpiece edge image and the workpiece constant surface region, the workpiece constant edge image including a second edge image of the workpiece constant surface region;

performing pattern-matching between the master constant edge image and the workpiece constant edge image so as to match the first edge image and the second edge image to acquire a first deviation amount between the master constant edge image and the workpiece constant edge image as a correction amount for the workpiece welding point;

correcting the workpiece welding point by the correction amount to generate a corrected processing program for welding the workpiece; and

controlling a welding robot to weld the workpiece based on the corrected processing program.

5. The control method for a welding machine according to claim 4 , further comprising:

estimating the master constant surface region based on the master edge image and the first coordinates to acquire the master constant surface region;

estimating the workpiece constant surface region based on the workpiece edge image and the second coordinates to acquire the workpiece constant surface region;

acquiring the first edge image in the master constant surface region; and

acquiring the second edge image in the workpiece constant surface region.

6. The control method for a welding machine according to claim 4 , wherein the position on the photographed master image of the first coordinates is manually input to the welding machine by an operator.

7. The control method for a welding machine according to claim 4 , further comprising:

aligning the master edge image and the workpiece edge image with each other to acquire a second deviation amount between the master edge image and the workpiece edge image; and

determining the second coordinates by shifting the first coordinates by the second deviation amount.