Laser Distance Sensor Calibration for Elongated Metallurgical Tools

The patent introduces an external calibration device as an intermediary between the robot and the elongated tool. This calibration device includes a reference coordinate system and measurement markers that mediate the calibration process, enabling precise measurement of the tool's position and orientation without relying solely on the robot's internal calibration systems. The intermediary device compensates for manufacturing and assembly errors by providing an independent reference framework.

The patent replaces traditional mechanical calibration methods with an optical measurement system. The external calibration device uses optical sensors and measurement markers to detect the tool's position and orientation, substituting mechanical contact-based calibration with non-contact optical measurement. This substitution enables higher precision calibration while reducing mechanical wear and assembly complexity.

The patent segments the calibration system into distinct functional modules: the external calibration device with reference coordinate system, the measurement markers attached to the tool, the optical sensing system, and the data processing unit. This segmentation allows each component to be optimized independently and simplifies the overall system architecture, making the complex calibration process more manageable and maintainable.

The external calibration device is designed with multi-functionality to reduce overall system complexity. The same calibration device can calibrate different elongated tools with varying lengths and diameters, and can perform both position and orientation calibration. The reference coordinate system serves multiple purposes including initial calibration, ongoing verification, and deformation detection, eliminating the need for multiple specialized devices.

The patent implements a feedback mechanism where the external calibration device continuously monitors the position and orientation of the standard temperature measurement/sampling gun during repeated operations. The measured data is fed back to the control system, which can detect deformation trends over time. When deformation exceeds predetermined thresholds, the system alerts operators to replace the gun, ensuring measurement precision is maintained while maximizing productive use of the tool.

The patent performs preliminary calibration and deformation assessment before the standard temperature measurement/sampling gun is put into repeated use. The external calibration device establishes baseline measurements and deformation thresholds in advance. During operation, pre-established criteria are used to quickly assess whether the tool has degraded beyond acceptable limits, enabling proactive replacement before precision is compromised.