Optical End-Tool Metrology for Precise Position and Orientation Tracking
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Solution Overview
Problem
Existing robot systems face limitations in achieving high accuracy and reliability for position and orientation determination, particularly in manufacturing and workpiece inspection processes, due to factors such as rotary encoder performance and mechanical stability, which can result in significant time consumption and suboptimal accuracy across various orientations.
Innovation Solution
A metrology system is integrated with a movement system, utilizing a light beam source configuration and sensors to determine the position and orientation of an end tool with enhanced accuracy by directing light beams to fixed sensors, processing measurement signals, and employing coherent light sources and diffractive optical elements to produce measurement spots on the sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional position sensors (rotary encoders) are used to determine robot position and orientation, then the system is simple and low cost, but the measurement precision is limited to approximately 100 microns
Solution Approach 1:
The patent replaces mechanical position sensors (rotary encoders) with an optical measurement system using light beams and position-sensitive detectors. This substitution enables measurement precision in the micron range, significantly improving accuracy from 100 microns to micron-level precision, while accepting increased system complexity through the addition of optical components.
2Measurement precision
If calibration techniques are used to improve robot system accuracy, then measurement precision improves, but significant time is consumed in the calibration process
Solution Approach 1:
The patent implements a self-measuring system where the robot system automatically determines its own position and orientation using the optical measurement system. The system continuously tracks its configuration without requiring external calibration, enabling real-time accurate measurement and eliminating the need for time-consuming periodic calibration procedures.
3Measurement precision
If photogrammetry systems are used to achieve high accuracy position and orientation determination, then measurement precision improves, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts and utilizes only the essential functional elements needed for accurate measurement: light sources, light beams, and position-sensitive detectors. By removing unnecessary complexity from photogrammetry systems and focusing on core optical measurement principles, the system achieves high precision while reducing overall system complexity and cost.
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
The system provides improved accuracy and reliability in determining the position and orientation of the end tool, offering higher precision than conventional methods and reducing complexity and cost compared to photogrammetry systems.
Implementation Method 1
The light beam source configuration is configured to direct light beams to light beam sensors of the sensor configuration to indicate a position and orientation of the light beam source configuration
Implementation Method 2
employing coherent light sources and diffractive optical elements to produce measurement spots on the sensors
Data Source
AI summary
A metrology system is provided for use with a movement system that moves an end tool. The metrology system includes a sensor configuration, a light beam source configuration and a processing portion. The light beam source configuration directs light beams to light beam sensors to indicate a position and orientation of the light beam source configuration. The light beam source configuration is coupled to the end tool or to an end tool mounting configuration. Light beams that are directed toward the light beam sensors produce measurement spots in positions on the light beam sensors that cause the light beam sensors to produce corresponding measurement signals. A modulation portion is configured to modulate a current of one or more light sources of the light beam source configuration. The processing portion processes the measurement signals from the sensor configuration to determine a position and orientation of the light beam source configuration.