Robot Teaching With Detachable Vision Sensor Calibration
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Solution Overview
Problem
Existing robot teaching methods suffer from reduced accuracy due to errors in the posture of the robot, which are propagated to the attached vision sensor, affecting the calibration and precision of the teach position.
Innovation Solution
A method involving a detachable stereo camera vision sensor that measures a reference object and calibrates its relative relationship with the robot, allowing for accurate teaching by referencing this relationship after attachment, thereby isolating errors in the robot's posture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the vision sensor is attached to the robot for calibration, then the calibration process can be performed, but the robot's posture errors are propagated to the vision sensor, reducing measurement accuracy
Solution Approach 1:
The system separates the calibration process into two independent stages: first calibrating the vision sensor relative to the robot in a controlled state, then using this pre-calibrated relationship during actual operation. This segmentation prevents error propagation by establishing the sensor-robot relationship when robot errors are minimal or controllable.
Solution Approach 2:
The vision sensor calibration is performed in advance before actual robot operations. By pre-calibrating the sensor-robot coordinate transformation relationship, the system establishes accurate reference data that compensates for subsequent robot posture errors during teaching and measurement operations.
2Ease of operation
If the vision sensor is fixed to the robot, then the sensor can be used for teaching, but the sensor inherits the robot's posture errors, affecting teaching accuracy
Solution Approach 1:
The patent introduces an intermediary coordinate transformation relationship between the vision sensor and the robot. By establishing and storing the sensor-robot transformation matrix through pre-calibration, the system mediates between the sensor measurements and robot positions, allowing accurate teaching even when the robot has posture errors.
3Manufacturing precision
If the robot posture has errors, then the robot cannot achieve precise positioning, but attaching a vision sensor to correct this propagates the errors to the sensor
Solution Approach 1:
The system uses the pre-calibrated vision sensor-robot relationship as a feedback mechanism. By measuring object positions with the vision sensor and transforming these measurements using the pre-established coordinate relationship, the system can compensate for robot posture errors and achieve accurate positioning without propagating errors to the sensor measurements.
Data Source
AI summary
A robot system includes a robot, a vision sensor, and a controller. The vision sensor is configured to be detachably attached to the robot. The controller is configured to measure a reference object by using the vision sensor and calibrate a relative relationship between a sensor portion of the vision sensor and an engagement portion of the vision sensor, and teach the robot by referring to the relative relationship and by using the vision sensor, after the vision sensor is attached to the robot.