Robot Calibration Control via Visual Servo and Force Feedback
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Solution Overview
Problem
Current robot calibration methods require extensive time and resources, especially in manufacturing environments where multiple types of work are frequently changed, leading to increased productivity losses due to the need for repeated calibration processes.
Innovation Solution
A robot system that performs new tasks without recalibrating its joint information unless necessary, using visual servo control or force control to adjust its position and posture based on image pickup or force feedback, thereby reducing unnecessary calibration procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If robot calibration is performed every time work is changed, then positioning accuracy is maintained, but productivity decreases due to repeated calibration time
Solution Approach 1:
The system changes the calibration execution parameter from 'always execute' to 'execute only when necessary' by introducing work type classification. When the work type remains the same, calibration is skipped; when it changes, calibration is performed. This parameter change resolves the contradiction by making calibration execution conditional rather than absolute.
Solution Approach 2:
The invention extracts the calibration operation from the mandatory sequence and makes it optional based on work type changes. By separating calibration from the standard work execution flow and placing it only in necessary scenarios, the system maintains positioning accuracy when needed while eliminating unnecessary calibration steps that reduce productivity.
2Loss of time
If simplified calibration is performed, then calibration time is reduced, but positioning accuracy may be insufficient for high-precision work
Solution Approach 1:
The system applies partial calibration action by performing calibration only for the specific joint or axis that requires adjustment rather than full-system calibration. When work type changes, only the necessary calibration steps are executed, reducing calibration time while maintaining sufficient positioning accuracy for the specific work requirements.
Solution Approach 2:
The calibration depth parameter is changed based on work type. For simple work type changes, simplified calibration is performed; for complex work type changes or when high precision is required, full calibration is executed. This dynamic parameter adjustment resolves the contradiction between calibration time and positioning accuracy.
3Productivity
If visual servo control is used, then calibration frequency is reduced, but system complexity increases
Solution Approach 1:
The invention replaces mechanical calibration adjustment with visual servo control. Instead of physically recalibrating the robot system every time work changes, the visual servo system uses image processing and feedback control to automatically adjust positioning. This substitution reduces calibration frequency and increases productivity while adding visual sensing and control software complexity.
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 the processing load and time required for calibration, improving productivity by allowing the robot to adapt to different tasks without the need for frequent recalibration, while maintaining accuracy through visual servo or force control adjustments.
Implementation Method 1
picking up images of an image pickup target object a plurality of times when the robot shifts from a first posture to a second posture different from the first posture
Implementation Method 2
an end effector provided with a force sensor, and after the i-th work, the robot may perform the i+1-th work by bringing the end effector into contact with an object
Data Source
AI summary
A robot performs, after i-th (i is a natural number) work, i+1-th work different from the i-th work and performs, after j-th (j is a natural number satisfying j≠i) work, j+1-th work different from the j-th work. The robot performs the i+1-th work after the i-th work without changing information concerning correction in a joint of the robot during the i-th work, performs robot calibration after the j-th work, and performs the j+1-th work after performing the robot calibration.