Robot Arm Calibration via Light Beam Positioning
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Solution Overview
Problem
Robot arms face challenges in maintaining precision over time due to mechanical offsets and deviations caused by maintenance, such as motor or gear replacements, making it difficult to ensure precision during long-term use and requiring in-line calibration on the production line.
Innovation Solution
A robot arm calibration device and method utilizing a light emitter, light sensing module, and cooperative motion controller to emit and receive a light beam, convert image data, calculate error values, and adjust motion parameters to correct positional precision, ensuring accurate alignment and reducing offset errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robot arms are used for long time or undergo maintenance, then mechanical offset and deviation occur, but precision is lost
Solution Approach 1:
The calibration device performs preliminary calibration actions by establishing reference positions and motion parameters before actual production work begins. The system pre-determines the relationship between robot arm motions and light beam positions, creating a baseline for detecting and correcting precision deviations during operation.
Solution Approach 2:
The system implements continuous feedback by using the light sensing module to detect the actual position of the light beam, comparing it with expected positions based on motion parameters, and generating correction data when deviations are detected. This feedback loop enables real-time precision maintenance without interrupting production.
2Manufacturing precision
If traditional calibration methods are used, then precision can be restored, but production line operation is interrupted
Solution Approach 1:
The calibration system enables continuous operation by performing calibration measurements during normal production work. The light emitter and sensing module operate concurrently with robot arm production tasks, allowing precision verification and correction without stopping the production line, thus maintaining continuous useful action.
Solution Approach 2:
The system provides self-service calibration capability where the robot arm itself participates in the calibration process by moving the light emitter to reference positions and the sensing module to measurement positions. This self-calibration approach eliminates the need for external calibration equipment and operators, maintaining production flow.
3Reliability
If in-line calibration is implemented, then precision can be maintained during production, but device complexity increases
Solution Approach 1:
The light beam serves as an intermediary carrier that transfers position information between the robot arm and the calibration system. Instead of directly measuring complex mechanical parameters, the system uses optical intermediaries (light emitter and sensing module) to indirectly detect position deviations, simplifying the measurement approach while maintaining accuracy.
Solution Approach 2:
The system replaces traditional mechanical measurement and calibration mechanisms with an optical-based approach. Instead of using mechanical gauges, contact probes, or complex positioning fixtures, the invention uses light emission and detection to establish reference positions and measure deviations, reducing mechanical complexity while enabling in-line 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
The solution effectively corrects precision errors in robot arms, maintaining mechanical accuracy and enabling in-line calibration, thereby addressing the challenge of maintaining precision over time and during cooperative movements.
Implementation Method 1
The light emitter is disposed on at least one robot arm to emit a light beam
Implementation Method 2
The light sensing module is disposed on at least another robot arm to receive the light beam and the light beam is converted into a plurality of image data
Data Source
AI summary
A robot arm calibration device is provided, which includes a light emitter, a light sensing module, a cooperative motion controller and a processing module. The light emitter is disposed on at least one robot arm to emit a light beam. The light sensing module is disposed on at least another robot arm to receive the light beam and the light beam is converted into a plurality of image data. The cooperative motion controller is configured to drive the light emitter and light sensing module on at least two robot arms to a corrected position and a position to be corrected, respectively. The processing module receives the image data and the motion parameters of the at least two robot arms to calculate an error value between the corrected position and the position to be corrected, and analyzes the image data to output a corrected motion parameter for modifying motion command.