Laser Intersection Robot Calibration System
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Solution Overview
Problem
Existing industrial robot calibration methods are costly and time-consuming, and they do not provide sufficient accuracy for applications like body-in-white, resistance welding, material handling, and MIG welding, where precise calibration is not always necessary.
Innovation Solution
A robot calibration system using a pair of laser beams intersecting at a 90-degree angle, with additional laser planes to adjust the robot's angular positions, allowing for off-line programming and recalibration by projecting laser planes onto the robot tool, enabling the user to visually define and adjust the reference coordinate system on the manufacturing shop floor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used, then measurement accuracy is improved, but calibration time and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical measurement systems with a laser-based optical system. The laser beam provides a precise reference axis that the robot tool must align with, eliminating the need for cumbersome mechanical fixtures and manual measurement procedures. This substitution maintains high measurement precision while dramatically reducing calibration time and complexity.
Solution Approach 2:
The patent changes the calibration approach from measuring multiple points and calculating transformations to a direct alignment method where the robot tool is positioned and oriented to match a laser-defined reference frame. This parameter change simplifies the calibration process by reducing the number of measurements required while maintaining accuracy through direct visual alignment with the laser beam.
2Measurement precision
If complex calibration systems are used, then calibration precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential calibration function to its simplest form: a laser beam defining a reference axis. By removing unnecessary complex components such as multiple calibration objects, complex fixtures, and elaborate measurement systems, the invention achieves high precision through a single, simple laser reference that the robot tool aligns with directly.
Solution Approach 2:
The patent replaces complex mechanical calibration systems with a simple laser-based optical system. The laser provides a clean, unambiguous reference that eliminates the need for complex mechanical fixtures, multiple measurement devices, and complicated alignment procedures, thereby reducing device complexity while maintaining or improving precision.
3Measurement precision
If traditional calibration methods are used, then measurement accuracy is maintained, but ease of operation decreases
Solution Approach 1:
The patent replaces difficult manual alignment procedures with a visual laser alignment system. The laser beam provides a clear, visible reference that guides the operator in positioning and orienting the robot tool, making the calibration process intuitive and easy to perform while maintaining high accuracy through direct visual feedback.
Solution Approach 2:
The patent uses the visible laser beam as a visual reference that changes the operator's perception of spatial relationships. The bright laser line provides immediate visual feedback on alignment status, making it easy for operators to understand whether the robot tool is correctly positioned and oriented relative to the reference frame, thereby improving ease of operation.
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 the calibration process, improves precision, reduces investment and operating costs, and allows for accurate recalibration of robotic paths without re-teaching the robot's path, enhancing the accuracy of industrial robots in various manufacturing applications.
Implementation Method 1
A robot calibration system using a pair of laser beams intersecting at a 90-degree angle
Implementation Method 2
with additional laser planes to adjust the robot's angular positions, allowing for off-line programming and recalibration by projecting laser planes onto the robot tool
Data Source
AI summary
The calibration device combines a work object with an industrial robot and a robot tool. The work object uses a pair of beam projecting lasers and three plane projecting lasers, the laser beams intersecting at a laser intersecting point. The laser intersection point of the laser beams and laser planes represent the location of the reference coordinate system which is selected to be the origin of the robot path being downloaded from the off-line programming. Once this off-line programming is created, the work object is placed onto the fixture on the manufacturing shop floor in the same place as the CAD environment. The user then manipulates the TCP into position of the laser intersection point and the laser planes. The robot is then manipulated down a first laser with the TCP recording a second point along a first laser beam and recording a third point along the opposing laser beam.