Robot Controller Multi-Region Calibration for Positioning Accuracy
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Solution Overview
Problem
Existing robot calibration methods focus on improving positioning accuracy within a limited measurement region, leading to decreased accuracy in other areas due to elastic deformation and backlash, especially when calibrating the whole movable range of a robot.
Innovation Solution
A robot controller that specifies multiple measurement regions within the robot's movable range, executes calibrations in each region, and stores results to identify and calibrate a new region where differences in mechanical parameters exceed a threshold, ensuring high positioning accuracy across the entire range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is executed in a limited measurement region, then positioning accuracy in that region is improved, but positioning accuracy in other regions decreases due to elastic deformation and backlash
Solution Approach 1:
The movable range of the robot is divided into multiple measurement regions (first, second, third, etc.) along the movement direction. Calibration is performed separately in each region, allowing the system to address positioning accuracy issues locally in each segment while maintaining reliability across the entire range. This segmentation enables targeted calibration without requiring a single large measurement region.
Solution Approach 2:
The system performs preliminary calibration in multiple regions before actual operation. By pre-calibrating multiple measurement regions and storing their respective mechanical parameters, the system prepares accurate positioning data for different areas in advance, eliminating the need for on-the-fly calibration and ensuring reliability across all regions during operation.
2Measurement precision
If multiple measurement regions are specified for calibration, then overall positioning accuracy is improved, but the complexity of the calibration process increases
Solution Approach 1:
The robot performs calibration operations autonomously by automatically moving between measurement regions and executing calibration procedures in each region. The system self-manages the complex multi-region calibration process without requiring external intervention, reducing the operational complexity despite calibrating multiple areas.
Solution Approach 2:
The system uses feedback from calibration results in one region to determine whether additional measurement regions need to be calibrated. The specifying section decides whether to specify a third measurement region based on calibration results from the first and second regions, allowing the calibration process to adapt dynamically and avoid unnecessary calibration steps.
3Measurement precision
If the entire movable range is calibrated, then positioning accuracy is improved across all regions, but the time and cost of calibration increases
Solution Approach 1:
Instead of calibrating the entire movable range uniformly, the system performs calibration in selected measurement regions that are sufficient to achieve the required positioning accuracy. The specifying section determines the appropriate number and location of measurement regions based on calibration results, avoiding unnecessary calibration in areas that already meet accuracy requirements.
Solution Approach 2:
The movable range is segmented into multiple measurement regions, allowing calibration to be performed in distributed segments rather than requiring a single comprehensive calibration of the entire range. This segmentation enables parallel or sequential calibration of manageable regions, reducing the time and complexity compared to calibrating the whole range as one unit.
Data Source
AI summary
A robot controller, a measurement system and a calibration method, by which measurement regions for improving positioning accuracy of a robot can be appropriately generated. First and second measurement regions are specified in a movable range of the robot, the calibration of a mechanical parameter of the robot is executed in each measurement region, and calibration results are stored as first and second calibration results. When the difference between the calibration results exceeds a predetermined threshold, a third measurement region is specified between the first and second measurement regions, and the calibration is further executed in the third measurement region. The result of the further calibration is stored as a third calibration result.