Laser Crosshair Calibration for Robotic Tool Alignment
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Solution Overview
Problem
Current robotic work object cell calibration systems are costly, time-consuming, and require specialized equipment and personnel, necessitating recalibration for each tool and location, which increases investment and operating costs and reduces precision.
Innovation Solution
A robotic work object cell calibration system utilizing a work object with beam-projecting lasers that emit a crosshair at a tool contact point (TCP) to adjust yaw, pitch, and roll, allowing for alignment and calibration without additional computers or software, using existing body-in-white procedures and personnel, and allowing for tool changes without recalibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration systems are used, then measurement accuracy can be achieved, but the system becomes costly and time-consuming with specialized equipment requirements
Solution Approach 1:
The patent replaces complex mechanical measurement devices with a laser-based optical system. The laser emitter projects beams that are detected by sensors, eliminating the need for expensive mechanical measuring instruments while maintaining calibration accuracy. This substitution of mechanical systems with optical fields directly addresses the contradiction by reducing device complexity while preserving measurement precision.
Solution Approach 2:
The patent creates a virtual model of the workpiece that mirrors its physical characteristics. By projecting laser beams and creating a digital representation of the workpiece geometry, the system captures spatial information without requiring direct physical measurement. This copying approach simplifies the physical measurement system while maintaining accurate calibration data.
2Measurement precision
If recalibration is performed for each tool and location, then calibration accuracy is maintained, but teaching time and operating costs increase
Solution Approach 1:
The patent creates a universal calibration system that can accommodate multiple tools and locations without requiring separate calibration procedures for each. The laser-based workpiece model serves as a common reference framework that any tool can use, eliminating the need for repeated recalibration when changing tools or locations. This multi-functionality directly reduces teaching time while maintaining calibration accuracy.
Solution Approach 2:
The patent performs calibration by creating a comprehensive virtual model of the workpiece and its spatial relationships in advance. This preliminary action establishes a reference framework that can be reused for multiple tools and locations, eliminating the need for repeated calibration procedures. By doing the calibration work once rather than repeatedly, the system significantly reduces teaching time while maintaining accuracy.
3Measurement precision
If specialized calibration equipment is used, then measurement accuracy improves, but investment and operating costs increase
Solution Approach 1:
The patent replaces expensive, specialized calibration equipment with a more economical laser-based system. The laser emitter and detectors are significantly cheaper than traditional mechanical measurement devices, while still providing accurate calibration data. This substitution of expensive equipment with more affordable alternatives directly reduces investment costs while maintaining measurement precision.
Solution Approach 2:
The patent substitutes mechanical measurement equipment with an optical laser system. The laser-based approach uses light fields instead of mechanical contact probes, eliminating the need for expensive mechanical measuring instruments. This substitution dramatically reduces equipment investment while maintaining or improving calibration accuracy through non-contact optical measurement.
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
This system simplifies calibration, reduces costs, and improves precision by allowing for tool changes without recalibration, using existing infrastructure and personnel, and ensures accurate alignment of robot tools with existing body-in-white procedures, thereby decreasing teaching time and investment costs.
Implementation Method 1
an emitter attached to the robot or its peripheral and emits a laser beam and a receiver also mounted to the robot or its peripheral at a point to permit calibration and for receiving the laser beam
Data Source
AI summary
The robotic work object cell calibration system includes a work object. The work object emits a pair of beam-projecting lasers acting as a crosshair, intersecting at a tool contact point (TCP). The work object emits four plane-projecting lasers are used to adjust the yaw, pitch, and roll of the robot tool relative to the tool contact point (TCP). The robotic work object cell calibration system provides a calibration system which is simpler, which involves a lower investment cost, which entails lower operating costs than the prior art, and can be used for different robot tools on a shop floor without having to perform a recalibration for each robot tool.