Robot Control Device Visual Servo Calibration Error Compensation
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Solution Overview
Problem
Current robot calibration methods require extensive human intervention and precision, leading to potential unintended contact with objects and damage, especially when calibration is insufficient or not performed.
Innovation Solution
A robot control device equipped with an image acquisition unit and a controller that initiates visual servo based on calibration errors, installation errors, and environmental factors, using a force detection unit to determine reference points and control the robot's motion, thereby reducing the risk of unintended contact and enhancing calibration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strict calibration is performed manually to achieve high precision, then positioning accuracy is improved, but calibration time and operational complexity increase significantly
Solution Approach 1:
The patent replaces manual mechanical calibration operations with an automated visual servo control system using image acquisition and computer vision algorithms. The system automatically detects object positions and adjusts robot movements without requiring manual intervention for calibration, thereby maintaining high positioning accuracy while dramatically reducing calibration time from several hours to minutes.
Solution Approach 2:
The system performs self-calibration through automated visual feedback. The image acquisition unit captures object positions, the controller processes this visual information to determine positioning errors, and the system automatically compensates for these errors without external intervention, enabling the robot to calibrate itself rapidly and repeatedly.
2Ease of operation
If calibration is not performed or performed insufficiently to reduce calibration burden, then operational simplicity is improved, but risk of unintended contact and damage increases
Solution Approach 1:
The patent implements continuous visual feedback during robot operations. The image acquisition unit continuously monitors object positions, and the controller uses this feedback to dynamically adjust robot movements in real-time. This feedback mechanism ensures that even without extensive preliminary calibration, the system maintains safe operating distances and prevents unintended contact by constantly adapting to actual object positions.
Solution Approach 2:
The system performs preliminary visual scanning and position detection before executing robot movements. By acquiring images and calculating positioning errors in advance, the system prepares safe trajectories that account for actual object locations, thereby preventing unintended contact before it occurs while minimizing calibration requirements.
3Productivity
If visual servo control is started early to reduce calibration burden, then calibration efficiency is improved, but risk of collision with object increases
Solution Approach 1:
The patent implements dynamic switching between different control modes based on real-time conditions. The system transitions from teaching playback control at larger distances to visual servo control when closer to the object, with switching conditions determined by actual positioning errors and object distances detected through image acquisition. This dynamic adaptation allows early initiation of visual servo while maintaining collision avoidance through conditional switching.
Solution Approach 2:
The system dynamically changes control parameters based on measured positioning errors and object distances. When the robot approaches the object, the controller adjusts velocity profiles, acceleration rates, and safety margins based on real-time visual feedback. These parameter changes enable aggressive yet safe approach trajectories that maximize calibration efficiency while preventing collisions through adaptive parameter adjustment.
Data Source
AI summary
An image acquisition unit acquires an image including an object, and a controller starts a visual servo using the acquired image, on the basis of at least one of an error in calibration, an error in installation of a robot, an error resulting from the rigidity of the robot, an error of a position where the robot has gripped the object, an error regarding imaging, and an error regarding a work environment. Additionally, the controller starts the visual servo when the distance between one point of a working unit of the robot and the object is equal to or greater than 2 mm.