Laser Work Object for Robotic Tool Calibration
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Solution Overview
Problem
Current robotic work object cell calibration methods are costly, time-consuming, and require specialized equipment and personnel, failing to efficiently calibrate robots for use with different tools without retraining or additional software, and do not account for the 'real-world' position of fixtures and peripherals.
Innovation Solution
A calibration method using a work object with beam-projecting lasers to align and adjust the robot tool's roll, yaw, and pitch, allowing for precise calibration without additional computers or software, utilizing existing body-in-white procedures and personnel, and enabling alignment with existing CAD simulation software.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration equipment and methods are used, then measurement accuracy can be achieved, but calibration time and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical measurement devices with a laser-based optical system. The laser emitter and receiver system substitutes traditional mechanical measuring instruments, enabling faster calibration without sacrificing accuracy. The laser beam provides precise measurement references that eliminate the need for physical contact and complex mechanical setups.
Solution Approach 2:
The patent creates a virtual model of the workpiece that mirrors its physical characteristics. This digital copy allows the robot to be calibrated against the virtual representation, which can be rapidly generated and modified without physical intervention. The virtual model serves as a reference that speeds up the calibration process while maintaining measurement fidelity.
2Measurement precision
If specialized calibration equipment is used, then calibration precision improves, but device complexity and cost increase
Solution Approach 1:
The laser emitter unit serves multiple functions: it emits laser beams for measurement, provides visual alignment references, and can be mounted on various robot types and configurations. This multi-functional design eliminates the need for separate specialized equipment for each calibration task, reducing overall system complexity while maintaining precision.
Solution Approach 2:
The patent introduces a laser beam as an intermediary between the measurement system and the robot. Instead of direct mechanical contact or complex sensor arrays, the laser beam acts as a simple yet precise mediator that transfers measurement information, simplifying the overall system architecture while achieving high calibration accuracy.
3Measurement precision
If traditional calibration methods are used, then robot positioning accuracy is improved, but adaptability to different tools and fixtures decreases
Solution Approach 1:
The calibration system is designed to work with various robot tools and fixture types without requiring reconfiguration. The laser-based measurement approach and virtual modeling capability allow the same system to adapt to different workpiece geometries, robot end-effectors, and fixture configurations, maintaining positioning accuracy across diverse applications.
Solution Approach 2:
The patent employs dynamic virtual modeling that can be rapidly updated to reflect changes in the physical setup. When tools or fixtures are changed, the virtual model can be quickly modified to match the new configuration, allowing the calibration system to adapt dynamically without requiring physical remeasurement or system reconfiguration, thus maintaining both accuracy and versatility.
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 calibration time and costs, improves precision, and allows for seamless tool changes without retraining, ensuring accurate robot operation by aligning the robot tool with the 'real-world' position of fixtures and peripherals, enhancing operational efficiency and accuracy.
Implementation Method 1
a laser attached to the robot or its peripheral and emits a laser beam
Data Source
AI summary
The robotic work object cell calibration method includes a work object or emitter. Initially, placing the work object is placed in a selected position on a fixture or work piece on the shop floor. The work object emits a pair of beam-projecting lasers which intersect at a tool contact point and act as a crosshair. The robot tool is manipulated into the tool contact point. The work object emits four plane-projecting lasers which are used to adjust the roll, yaw, and pitch of the robot tool relative to the tool contact point. The robotic work object cell calibration method of the present invention increases the accuracy of the off-line programming and decreases robot teaching time.