Robot Scanning Recalibration Using 3D Calibration Spheres
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Solution Overview
Problem
Manufacturing robots face challenges in accurately recalibrating scanning devices to determine the position and three-dimensional shape of objects, leading to potential collisions and inefficiencies in the manufacturing process.
Innovation Solution
A method involving a scanning device that detects a calibration unit with multiple spheres to determine relative position and provide position corrections, using point cloud sensors like LIDAR or Structured Light Sensors, and optionally a laser tracker, to automatically adjust the robot's position and prevent collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual recalibration methods are used, then the scanning device can be recalibrated, but the process is time-consuming and prone to inaccuracies
Solution Approach 1:
The patent replaces manual mechanical recalibration operations with an automated optical measurement system. A scanning device captures point cloud data of calibration spheres, and a computing device automatically calculates position corrections, eliminating the need for time-consuming manual measurements and calculations while improving precision.
Solution Approach 2:
The system enables self-calibration by using the robot arm's own scanning device to detect calibration spheres and automatically compute position corrections. The manufacturing robot performs its own recalibration without requiring external manual intervention, reducing both time and potential human error.
2Productivity
If the scanning device is not accurately calibrated, then the manufacturing process continues, but collisions may occur and quality issues arise
Solution Approach 1:
The system performs preliminary calibration by detecting calibration spheres and calculating position corrections before the manufacturing robot begins its actual work. This advance calibration ensures the robot arm and tool are properly positioned, preventing collisions and quality issues during production while maintaining high efficiency.
Solution Approach 2:
The scanning device continuously monitors the position of calibration spheres and provides feedback to the computing device, which calculates position corrections. This feedback mechanism ensures the robot arm maintains accurate positioning throughout the manufacturing process, preventing collisions while preserving productivity.
3Measurement precision
If complex recalibration procedures are used, then positioning accuracy improves, but the ease of operation decreases
Solution Approach 1:
The patent replaces complex manual recalibration procedures with an automated optical system. The scanning device automatically captures point cloud data of calibration spheres, and the computing device performs complex calculations to determine position corrections, achieving high precision without requiring operator expertise or complex manual operations.
Solution Approach 2:
The system uses point cloud data (a digital copy of the physical calibration spheres) to perform recalibration instead of direct physical measurement. This digital copying approach simplifies the operation while maintaining high accuracy, as the computing device can precisely analyze the digital point cloud data without manual intervention.
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 method allows for precise and automatic recalibration, reducing time and inaccuracies in the manufacturing process, and preventing quality issues by compensating for deviations caused by tool deformation or collisions.
Implementation Method 1
The scanning device is configured to detect a point cloud of the object and its surroundings
Implementation Method 2
The scanning device can be a laser scanner, for example, such as a LIDAR, Time of Flight Sensor
Data Source
Figure 1~3
AI summary
The invention relates to a method for operating a manufacturing robot (1) comprising a robot arm (2) on which a tool (3) and a scanning device (4) are arranged, wherein the scanning device (4) is configured to determine the position and shape of an object (5), the method comprising the following steps: - Detecting a calibration unit (6), which comprises at least three spheres (7) and has a predetermined absolute position, by the scanning device (4); (S1) - Determining a relative position between the scanning device (4) and the calibration unit (6); (S2) - Determining at least one difference value between the absolute position and the relative position; and - Providing a position correction for determining the position of the object (5) by the scanning device (4) based on the at least one difference value. The invention further relates to a manufacturing robot (1).