Robot Calibration Accuracy Monitoring for Task Tolerance Checks
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Solution Overview
Problem
Robotic systems face challenges in maintaining calibration accuracy over multiple operation cycles, leading to potential task failures due to accumulated errors, as robots and sensors often shift from their initial calibrated poses, resulting in decreased precision and inability to meet accuracy tolerances.
Innovation Solution
A system that simulates a virtual representation of the operating environment to determine if robots can perform tasks within specified accuracy levels, monitors calibration accuracy changes, and prompts notifications for discrepancies, allowing for timely adjustments and optimization of calibration programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robots perform tasks using pre-programmed schedules, then task automation is achieved, but calibration errors accumulate over multiple operation cycles resulting in task failure
Solution Approach 1:
The system performs preliminary detection of calibration accuracy before tasks are executed. By measuring the calibration accuracy of robots and sensors in advance and comparing it against required accuracy tolerances, the system identifies calibration issues before they cause task failures, preventing error accumulation from affecting productivity
Solution Approach 2:
The system establishes a feedback loop where calibration accuracy is continuously monitored and measured. The detection results feed back into the calibration process, allowing operators to adjust and recalibrate components before errors accumulate to critical levels, thereby maintaining both automation reliability and task success rates
2Measurement precision
If calibration is performed manually in the operating environment, then calibration accuracy is optimized, but setup time and costs increase
Solution Approach 1:
The system replaces manual mechanical calibration processes with an automated optical measurement system. Cameras and image processing algorithms automatically detect robot poses and calculate calibration accuracy, eliminating time-consuming manual adjustment while maintaining or improving calibration precision
Solution Approach 2:
The system creates a virtual representation of the operating environment including robot models and sensor positions. By simulating and measuring calibration accuracy in this virtual copy, the system can evaluate calibration quality without requiring physical trial-and-error adjustments in the actual operating environment, significantly reducing setup time
3Manufacturing precision
If robots are calibrated to high precision initially, then task accuracy tolerance is met at the start, but calibration accuracy decreases after repeated operation cycles
Solution Approach 1:
The system implements continuous monitoring of calibration accuracy throughout operation cycles rather than performing discrete calibration checks. By continuously measuring the calibration accuracy of robots and sensors during repeated operations, the system detects drift as it occurs and can trigger recalibration before precision degradation affects task performance
Solution Approach 2:
The system performs preliminary detection of calibration accuracy changes after a specified number of operation cycles. By proactively measuring calibration status before precision degradation becomes critical, the system can schedule maintenance recalibration at optimal intervals, maintaining long-term calibration stability without excessive intervention
Data Source
AI summary
Methods, systems, and apparatus, including computer programs encoded on computer storage media, for measuring and reporting calibration accuracy of robots and sensors assigned to perform a task in an operating environment. One of the methods includes receiving a request to perform a calibration process for one or more robots in an operating environment; in response, performing the calibration process including executing a calibration program that generates movement data representing movements by the one or more robots within the operating environment; computing a measure of calibration accuracy from the movement data; receiving an input program to be executed in the operating environment; determining that the measure of calibration accuracy does not satisfy an accuracy tolerance of the input program; and in response, generating a notification representing that the measure of calibration accuracy generated from performing the calibration process does not satisfy the accuracy tolerance of the input program.