Dual-Camera End Effector Calibration for Fast 6D Positioning

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Solution Overview

Problem

Conventional end effector calibration methods for robotic systems are slow and cumbersome, requiring multiple passes through an infrared beam to accurately determine the position and orientation of the end effector, which hinders efficient calibration and precise robotic operations.

Innovation Solution

An end effector calibration system utilizing two camera assemblies with intersecting image capture paths, where an electronic controller processes image data from both cameras to quickly and accurately calibrate the position of the robot end effector, recognizing the tool type and assessing wear or assembly issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional infrared beam calibration methods are used, then the position of the end effector can be determined, but the calibration process becomes slow and cumbersome requiring several passes

Engineering Contradiction:

Improveposition determination accuracyVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the mechanical infrared beam breaking method with an optical vision-based system using cameras to detect the end effector position. The camera system captures images of the end effector, and the controller processes these images to determine position and orientation, eliminating the need for multiple physical passes through an infrared beam while maintaining measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses visual copying by capturing optical images of the end effector with cameras. Instead of physically interacting with the end effector through infrared beams, the system creates optical copies (images) of the end effector and processes these copies to determine its position and orientation, significantly reducing calibration time while maintaining accuracy.

Inventive Principle:

Principle #26Copying

2Reliability

If multiple passes through infrared beam are required for calibration, then position accuracy can be achieved, but the process becomes cumbersome and inefficient

Engineering Contradiction:

Improvecalibration accuracyVSAvoidcalibration process simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the complex mechanical process of multiple infrared beam passes with a simplified optical vision system. The camera-based system captures the end effector position in a single operation, and the controller automatically processes the visual data to achieve reliable calibration, making the process much easier to operate while maintaining accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The calibration system performs self-service by automatically capturing images of the end effector and processing the visual data to determine position and orientation without requiring manual intervention for multiple passes. The electronic controller automatically completes the calibration process based on the captured images, simplifying operation while ensuring reliable results.

Inventive Principle:

Principle #25Self-service

3Device complexity

If a single camera system is used for calibration, then the device complexity is reduced, but the measurement precision and speed are insufficient for six-dimensional tip calibration

Engineering Contradiction:

Improvecamera system structureVSAvoidsix-dimensional tip calibration accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent merges two camera systems to achieve six-dimensional tip calibration capability. By combining the data from two cameras with intersecting image capture paths, the system can determine both position and orientation of the end effector tip in three-dimensional space, achieving the required measurement precision without excessive complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent adds another dimension by using two cameras instead of one, creating intersecting image capture paths that enable six-dimensional measurement. This dimensional enhancement allows the system to accurately determine both position and orientation of the end effector tip, achieving the required calibration precision for complex robotic operations.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11260531B2End effector calibration assemblies, systems, and methods

Publication Date: 2022.03.01 ADVANCED SOLUTIONS LIFE SCIENCES LLC

AI summary

An end effector calibration assembly includes an electronic controller, a first camera assembly communicatively coupled to the electronic controller, and a second camera assembly communicatively coupled to the electronic controller. A first image capture path of the first camera assembly intersects a second image capture path of the second camera assembly. The electronic controller receives image data from the first camera assembly, receives image data from the second camera assembly, and calibrates a position of the robot end effector based on the image data received from the first camera assembly and the second camera assembly.