Laser Robot Calibration Using Scanned Jig Distance Mapping
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Solution Overview
Problem
Existing calibration methods for laser processing robots require precise positioning of the processing tool, which is time-consuming and inefficient, especially when the tool is replaced.
Innovation Solution
A calibration method that includes fixing a measurement jig with a prescribed shape to the base, providing the laser processing tool with two-dimensional scanning and distance measuring functions, and calculating a coordinate transformation function to correct the tool center point without precise alignment, using a six-axis articulated robot system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If precise positioning of the processing tool is performed during calibration, then calibration accuracy is improved, but calibration time increases significantly
Solution Approach 1:
The patent replaces manual mechanical positioning operations with an automated calibration system that uses a measurement jig and coordinate transformation calculations. The system automatically determines the tool center point by scanning the measurement target site and performing mathematical transformations, eliminating the need for time-consuming manual precise positioning while maintaining calibration accuracy.
Solution Approach 2:
The patent uses a measurement jig with a measurement target site that replicates the essential geometric features needed for calibration. Instead of requiring direct manipulation of the actual processing tool, the system creates a simplified copy (the measurement jig) that can be easily scanned and measured, thereby reducing calibration time while preserving the accuracy needed for tool center point determination.
2Measurement precision
If manual positioning operations are performed during calibration, then positioning precision can be achieved, but operational complexity increases
Solution Approach 1:
The calibration system performs self-service by automatically determining the tool center point through coordinate transformation calculations. The measurement jig is designed to be scanned automatically, and the system autonomously computes the transformation functions and corrects the tool center point coordinates without requiring manual positioning operations, thereby simplifying the calibration process while maintaining precision.
Solution Approach 2:
The patent introduces a measurement jig as an intermediary element between the processing tool and the calibration system. This intermediary object simplifies the calibration process by providing a standardized measurement target that can be easily scanned and measured, eliminating the need for complex manual positioning operations while ensuring accurate tool center point determination.
3Measurement precision
If complex positioning procedures are used for tool replacement calibration, then calibration accuracy is maintained, but productivity decreases
Solution Approach 1:
The patent implements preliminary action by pre-positioning the measurement jig at a known location on the base and pre-programming the scanning paths. When tool replacement occurs, the system can immediately perform calibration by scanning the pre-positioned measurement target and applying coordinate transformations, eliminating the need for time-consuming re-positioning procedures and thereby maintaining high productivity during tool changes.
Solution Approach 2:
The patent replaces complex mechanical positioning procedures with automated scanning and computational methods. The system uses laser scanning to automatically capture the measurement target site geometry and performs coordinate transformation calculations to determine the new tool center point, thereby maintaining calibration accuracy while significantly improving tool replacement efficiency.
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 method reduces the time required for calibration by eliminating the need for precise positioning of the laser processing tool, allowing for efficient recalibration when the tool is replaced, and simplifies the calculation of the coordinate transformation function.
Implementation Method 1
providing the laser processing tool with a function for two-dimensionally scanning a measurement laser beam
Implementation Method 2
a distance measuring function for receiving the measurement laser beam reflected at an object and for measuring a distance to the object
Data Source
AI summary
A calibration method for a laser processing robot, including: fixing a jig that includes a target-site to a base of the laser processing robot; placing a laser processing tool at a position where a laser beam is scanned with respect to the target-site, the laser processing tool having a function for two-dimensionally scanning the laser beam and a function for receiving the laser beam reflected at an object and for measuring a distance to the object; measuring distances to respective portions of the target-site by scanning the laser beam; calculating a coordinate transformation function for converting a position and orientation of the target-site, which is obtained based on the measured distances to the respective portions of the target-site, into an actual position and orientation of the target-site; and correcting a tool-center-point of the laser processing tool by the coordinate transformation function.