Construction Robot Optical Calibration for On-Site Manipulator Accuracy
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Solution Overview
Problem
Existing construction robots require costly and location-specific calibration using calibrated duplicates, limiting their ability to achieve high positional accuracy and necessitating off-site maintenance, such as when manipulators are replaced due to damage or wear.
Innovation Solution
A construction robot equipped with an optical sensor system on a mobile platform for autonomous calibration, allowing precise determination of manipulator position and orientation without external devices, enabling on-site calibration and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is carried out using a calibrated duplicate manipulator, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical calibration system (calibrated duplicate manipulator) with an optical measurement system. The optical sensor system captures images of the manipulator in different positions, and image processing algorithms automatically determine position and orientation data, eliminating the need for physical calibration artifacts and reducing system complexity.
Solution Approach 2:
The patent uses optical imaging to create a digital copy/representation of the manipulator's physical state. By capturing images and processing them to extract position and orientation information, the system creates a virtual model of the manipulator's configuration, which serves the same purpose as physical calibration artifacts but with reduced complexity.
2Measurement precision
If calibration is performed at a manufacturing site or repair workshop, then measurement precision is ensured, but loss of time and productivity decrease due to off-site calibration requirements
Solution Approach 1:
The patent enables the manipulator to perform its own calibration autonomously. The optical sensor system on the manipulator captures images, and the control unit automatically processes these images to determine position and orientation data and generate calibration information, eliminating the need for external calibration equipment and personnel.
Solution Approach 2:
The optical sensor system serves multiple functions: it acts as both a measurement tool for calibration and a positioning sensor for operational guidance. This multi-functionality allows the same system to perform calibration on-site during normal operations without requiring separate calibration equipment or taking the manipulator offline.
3Ease of operation
If an optical sensor system is used for autonomous calibration, then ease of operation and productivity are improved, but manufacturing precision requirements increase for the sensor system
Solution Approach 1:
The patent implements a feedback mechanism where the optical sensor system continuously monitors the manipulator's position and orientation, compares the measured values with target values, and automatically adjusts the manipulator's configuration. This closed-loop control compensates for minor precision variations in the optical sensor system and ensures accurate calibration results.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The optical sensor system enables precise, cost-effective on-site calibration of manipulators, ensuring high positional accuracy and flexibility in construction work without the need for additional calibration devices.
Implementation Method 1
an optical sensor system which is configured to detect a position and/or orientation of the manipulator, in particular a tool arranged on the manipulator, relative to the mobile platform
Data Source
AI summary
A construction robot for carrying out construction work on a construction site object includes a mobile platform, a manipulator which is movable relative to the mobile platform, and an optical sensor system which is at least partially disposed on the mobile platform. A control unit is configured to determine, using the optical sensor system, a position and/or an orientation of a tool disposed on the manipulator relative to the mobile platform.