Robot-Conveyor Coordinate Calibration With Non-Contact Sensing
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Solution Overview
Problem
Calibrating a robot to a conveyor is a tedious and time-consuming process that requires expert skills and manual accuracy, affecting the precision of pick and place operations.
Innovation Solution
A method using a non-contact sensor, such as a vision sensor or radar, to detect the positions of the robot and conveyor in a non-contact manner, enabling automated and accurate calibration of the robot coordinate system with the conveyor coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration procedure is used, then calibration accuracy can be achieved with expert skills, but calibration time is excessive and requires expert knowledge
Solution Approach 1:
The patent replaces manual mechanical calibration operations with an automated optical measurement system. A camera captures images of calibration markers on the conveyor, and software automatically calculates coordinate transformations, eliminating the need for manual jogging and measurement while maintaining high precision.
Solution Approach 2:
The patent uses visual copying through camera imaging to capture the positions of calibration markers on the conveyor. Instead of manual physical measurement, the system creates digital copies of marker positions through images, which are then processed automatically to determine coordinate system relationships.
2Ease of manufacture
If manual calibration procedure is used, then calibration can be performed, but it requires expert skills and manual accuracy
Solution Approach 1:
The calibration system performs self-service by automatically capturing images of calibration markers, processing the image data, and calculating coordinate transformations without human intervention. The software autonomously completes tasks that previously required expert operators, making calibration accessible to non-experts.
Solution Approach 2:
The patent replaces complex manual operations with automated computer vision and image processing. The system substitutes human expertise with algorithmic processing of camera images, eliminating the need for operators to understand complex calibration procedures while maintaining accuracy.
3Productivity
If non-contact sensor is used for calibration, then calibration speed is improved and automation is achieved, but system setup complexity increases
Solution Approach 1:
The patent introduces calibration markers as intermediary objects that facilitate communication between the conveyor system and the camera. These markers serve as a simple interface that translates physical conveyor positions into visual information that can be easily captured and processed by the camera system.
Solution Approach 2:
The patent changes the measurement parameter from direct physical measurement to optical parameter detection. By using camera images and processing pixel coordinates, the system transforms the calibration problem into a 2D image processing task, which is computationally simpler and faster than traditional 3D mechanical measurement.
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
Facilitates a simple, fast, and precise calibration process that reduces downtime and reliance on manual skills, improving the accuracy of robot operations on conveyors.
Implementation Method 1
A method using a non-contact sensor, such as a vision sensor or radar, to detect the positions of the robot and conveyor in a non-contact manner
Data Source
Figure 1a~1b
Figure 2a~2b
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AI summary
Method for calibrating a robot coordinate system (Xbase, Xmi, Xtool) of a robot (12) with a conveyor coordinate system (Xcon) of a movable conveyor member (18), the method comprising providing a sensor (24) configured to detect positions of the robot (12) in a non-contact manner; detecting a position of the robot (12) when the conveyor member (18) is positioned at a first operating position; detecting a position of the robot (12) and/or of the conveyor member (18) by the sensor (24) in the sensor coordinate system (Xsen) when the conveyor member (18) is positioned at a second operating position different from the first operating position; and determining a relationship between the robot coordinate system (Xbase, Xmi, Xtool) and the conveyor coordinate system (Xcon) based on at least one detected position of the robot (12) in the sensor coordinate system (Xsen). A robot system (10) and a control system (16) are also provided.