Robot Calibration Using Image Data and Reference Marks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial robots require periodic calibration to maintain precise positioning due to wear, dimensional changes, and component replacements, which is time-consuming and inefficient with traditional measurement tools.
Innovation Solution
A system using image data to calibrate robots by capturing calibration images with a camera that includes robot reference marks and environment reference marks, determining actual positions, and calculating calibration offsets to adjust actuator positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement tools are used for robot calibration, then positioning accuracy can be maintained, but calibration time increases significantly
Solution Approach 1:
The patent replaces traditional mechanical measurement tools (such as laser scanners and contact probes) with an optical imaging system. A camera captures images of reference marks on the robot, and image processing algorithms automatically calculate positioning deviations. This substitution of mechanical measurement with optical measurement significantly reduces calibration time while maintaining high positioning accuracy, as the camera can capture multiple positions simultaneously and the automated image processing eliminates manual measurement steps.
2Measurement precision
If multiple measurement points are calibrated to improve accuracy, then positioning precision improves, but the complexity of the calibration process increases
Solution Approach 1:
The patent uses reference marks (visual copies) placed on the robot and in the environment to represent physical positions. These marks are captured by the camera and processed through image recognition to determine actual positions. By using visual copies instead of direct physical measurement, the system simplifies the calibration process while maintaining accuracy across multiple measurement points. The reference marks serve as easily detectable proxies for complex geometric features.
3Reliability
If periodic calibration is performed to compensate for wear and dimensional changes, then robot reliability is maintained, but productivity is reduced due to downtime
Solution Approach 1:
The patent performs calibration during setup and before production runs, establishing accurate positioning parameters in advance. The quick calibration method allows this preliminary action to be completed rapidly, minimizing interruption to production. By optimizing the calibration process to be faster and more efficient, the system maintains positioning reliability while reducing the time cost of periodic calibration, thereby preserving manufacturing productivity.
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 enables precise and efficient calibration of industrial robots by using image processing to determine and apply calibration offsets, improving positioning accuracy and reducing calibration time.
Implementation Method 1
A calibration image of the robot in the operating environment is captured using a camera and includes the at least one robot reference mark and the at least three environment reference marks
Data Source
AI summary
This disclosure provides systems and methods of robot calibration using imaging data. A mounting interface attaches to the sensor module to the robot system. A robot includes at least one positioning member, at least one joint connected to the at least one positioning member, at least one actuator for moving the at least one positioning member around the at least one joint, and at least one robot reference mark on the at least one positioning member. The operating environment includes at least three environment reference marks in fixed positions relative to the robot. A camera captures a calibration image and an actual position of the robot is determined based on the robot reference mark relative to the environment reference marks to determine a calibration offset between a reference position and the actual position using the calibration image.