Robot Optical Sensor Calibration Using Automated Multi-Pose Imaging

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Solution Overview

Problem

Manual calibration of optical sensors in robotic applications is inconsistent, time-consuming, and requires separate image collections for intrinsic and extrinsic calibration, making it prone to errors and reliant on operator skill.

Innovation Solution

An automated system that uses a robot arm, a calibration chart, and processors to determine poses, capture images, and calculate intrinsic and extrinsic calibration parameters, allowing for simultaneous calibration of optical sensors with reduced manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual calibration procedures are used with separate image collections for intrinsic and extrinsic calibration, then calibration can be performed in a lab environment with controlled conditions, but the process is time-consuming, inconsistent, and relies on operator skill

Engineering Contradiction:

Improvecalibration accuracyVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent combines intrinsic and extrinsic calibration into a single automated process that captures both calibration parameters simultaneously from one set of images, eliminating the need for separate manual calibration stages and reducing overall calibration time while maintaining accuracy

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces manual mechanical calibration operations with an automated computer vision system that uses image processing algorithms to determine both intrinsic and extrinsic calibration parameters automatically, removing dependence on operator skill and improving consistency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual calibration is performed by operators, then calibration can be completed in a lab environment, but the process is inconsistent and prone to errors due to reliance on operator skill

Engineering Contradiction:

Improvecalibration consistencyVSAvoidcalibration process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The calibration system performs self-calibration automatically using computer vision algorithms processed by a computing device, eliminating the need for human operators to manually adjust and calibrate the robotic system, thereby improving consistency and reducing human error

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual calibration operations with an automated computer vision-based system that uses image processing and algorithmic computation to determine calibration parameters, transforming a skill-dependent manual process into a consistent automated procedure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If separate image collections are used for intrinsic and extrinsic calibration, then each calibration type can be performed independently, but the overall calibration process becomes more complex and time-consuming

Engineering Contradiction:

Improvecalibration efficiencyVSAvoidcalibration process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges intrinsic and extrinsic calibration into a unified automated process where a single set of images captured by the robotic system is used to compute both calibration parameters simultaneously, streamlining the workflow and improving efficiency

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The computing device performs multiple calibration functions (both intrinsic and extrinsic calibration) using a single automated image processing pipeline, making the system multi-functional and eliminating the need for separate specialized procedures

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11254019B2Automatic calibration for a robot optical sensor

Publication Date: 2022.02.22 THE BOEING CO

AI summary

Systems and methods are provided for automatic intrinsic and extrinsic calibration for a robot optical sensor. An implementation includes an optical sensor; a robot arm; a calibration chart; one or more processors; and a memory storing instructions that cause the one or more processors to perform operations that includes: determining a set of poses for calibrating the first optical sensor; generating, based at least on the set of poses, pose data comprising three dimensional (3D) position and orientation data; moving, based at least on the pose data, the robot arm into a plurality of poses; at each pose of the plurality of poses, capturing a set of images of the calibration chart with the first optical sensor and recording a pose; calculating intrinsic calibration parameters, based at least on the set of captured images; and calculating extrinsic calibration parameters, based at least on the set of captured images.