Industrial Robot Commissioning Tool Error Estimation by Image Rotation
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Solution Overview
Problem
Existing methods for industrial robot commissioning, such as using a stylus and touchscreen, introduce systematic errors due to offsets between the stylus and operational tool positions, and between touch and display frame coordinate systems, which are not accurately calculated by prior art.
Innovation Solution
A method and apparatus that drive the operational tool to rotate and capture images to calculate the offset between the stylus and operational tool, and between touch and display frame coordinate systems, iteratively refining the estimates to improve precision without adding hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a stylus and touchscreen are used as commissioning tools, then the commissioning process becomes automated and convenient, but systematic errors are introduced due to offsets between the stylus and operational tool positions
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated image-based measurement system. The application camera captures images of the operational tool during rotation, and the commissioning tool automatically calculates the offset based on image analysis, eliminating the need for manual measurement and reducing human error while maintaining high precision.
Solution Approach 2:
The patent changes the measurement parameter from direct physical contact (stylus touching touchscreen) to optical measurement (camera capturing images). By using image processing to determine the operational tool's position and calculate offsets, the system achieves higher measurement precision while maintaining automation and convenience.
2Extent of automation
If a stylus is used for Tool Center Point calibration, then automated calibration is achieved, but the calibration accuracy deteriorates due to the fixed offset between stylus and operational tool positions
Solution Approach 1:
The patent introduces an application camera as an intermediary device between the stylus and the operational tool. The camera captures images of the operational tool during rotation, allowing the system to calculate the offset between the stylus position and operational tool position through image analysis, thereby eliminating the direct contact error while maintaining automation.
Solution Approach 2:
The patent creates a visual copy (image) of the operational tool using the application camera. Instead of relying on the physical stylus contact point, the system uses the captured image to determine the operational tool's position and calculate offsets, achieving both automation and high precision through optical copying and analysis.
3Productivity
If touchscreen coordinate systems are used for commissioning, then automated positioning is achieved, but accuracy deteriorates due to offsets between touch frame and display frame coordinate systems
Solution Approach 1:
The patent replaces the touchscreen's coordinate system dependency with an image-based coordinate system from the application camera. By capturing images and analyzing the operational tool's position in the image coordinate system, the system calculates offsets without being affected by the touchscreen's internal coordinate system offsets, maintaining both efficiency and accuracy.
Data Source
AI summary
The present disclosure relates to a method and apparatus for estimating a systematic error of a commissioning tool of an industrial robot, the industrial robot including an operational tool and an application camera, the commissioning tool including a touchscreen and a stylus, the method including: a driving step of driving the operational tool to rotate around a preset rotation axis; a first image obtaining step of obtaining a plurality of first images of the operational tool during rotation; and a first offset calculating step of calculating a first offset of the stylus relative to the operational tool according to the plurality of first images, so as to obtain the systematic error.