Robot Calibration Using Integrated Optical Sensing
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Solution Overview
Problem
Current robot calibration methods are hindered by high apparatus costs and excessively long calibration times due to the need for external monitoring devices and the complexity of calculating transformation matrices, especially in miniature and diversified production environments.
Innovation Solution
A robot positioning and calibration method that integrates an optical sensing device directly on the robot, using a calibration plate to calculate transformation matrices and distortion error values through Bundle Adjustment, eliminating the need for external devices and allowing for faster and more cost-effective calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external monitoring device is used for robot calibration, then the calibration can be performed, but the apparatus cost increases
Solution Approach 1:
The patent merges the camera device with the robot body, making the robot both the object being calibrated and the device performing calibration. The camera is integrated onto the robot's end effector or body, eliminating the need for separate external monitoring devices, thereby reducing apparatus cost while maintaining calibration capability
Solution Approach 2:
The robot performs calibration on itself by using its integrated camera to capture images of calibration objects during its own movement. The robot's control unit processes the captured images and calculates transformation matrices autonomously, making the system self-sufficient and eliminating dependency on external calibration equipment
2Reliability
If an external monitoring device is connected to the robot before calibration, then calibration can be performed, but the calibration time increases
Solution Approach 1:
The camera device is pre-integrated onto the robot body during manufacturing, so no additional connection or setup is needed before calibration. The optical sensing device and control unit are already configured and connected, allowing calibration to begin immediately when the robot needs it, eliminating pre-calibration setup time
Solution Approach 2:
The robot's integrated control unit autonomously processes calibration images and calculates transformation matrices without requiring external computation resources. This self-processing capability eliminates time delays associated with data transmission and external processing, enabling faster calibration cycles
3Measurement precision
If the camera captures and transmits images to an external device for processing, then transformation matrix calculation can be performed, but the calibration time increases
Solution Approach 1:
The control unit that processes images and calculates transformation matrices is integrated into the robot's own control system rather than being external. This merging of capture and processing functions within the same system eliminates data transmission delays and enables immediate processing of calibration images, reducing overall calibration time while maintaining calculation accuracy
Solution Approach 2:
The patent introduces a dedicated image processing module within the robot's control unit that acts as an intermediary between the camera and the main control system. This intermediary is optimized for rapid image processing and transformation matrix calculation, reducing processing time while ensuring accurate results
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 approach reduces apparatus costs and calibration time by enabling direct image capture and processing on the robot, allowing for precise calibration without additional hardware and enabling the consideration of distortion error values for improved precision.
Implementation Method 1
an optical sensing device is disposed on a front end of the robot... the optical sensing device captures a calibration plate image
Data Source
AI summary
A robot positioning method includes the following steps. A optical sensing device is configured at a front end of a robot. Then, the optical sensing device captures a calibration plate image, and a relative position of the optical sensing device with respective to a calibration plate is calculated according to a Bundle Adjustment. A robot calibration method includes the following steps. An optical sensing device is driven to rotate around a reference axis of a calibration plate, so as to calculate a translation matrix between the calibration plate and the robot, and the optical sensing device is driven to translate along three orthogonal reference axes of the calibration plate, so as to calculate a rotation matrix between the calibration plate and the robot.