Robot Tool TCP Calibration Using Multi-Pointer Target Alignment
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Solution Overview
Problem
Existing manufacturing robots face challenges in efficiently recovering the tool center point (TCP) after design changes or crashes, often requiring complex and costly third-party sensors for calibration.
Innovation Solution
A method and calibration device using a calibration tool with multiple pointers to determine the TCP by touching a fixed target, allowing for precise alignment without additional sensors, and employing an optimization algorithm to calculate rotation and translation for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If third-party sensors are used for TCP calibration, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The robot system performs self-calibration using its own existing sensors and tools without requiring external third-party measurement devices. The calibration process is executed autonomously by the robot arm moving the calibration tool to predetermined positions and the control unit calculating TCP based on sensor data from the robot's own sensors.
Solution Approach 2:
The calibration method uses the robot's existing sensors and control systems for multiple purposes - both for normal operation and for calibration. The same sensors used for positioning during manufacturing are reused for TCP calibration, eliminating the need for dedicated calibration sensors and reducing overall system complexity.
2Reliability
If traditional calibration methods are used after crashes or design changes, then recovery is possible, but time consumption increases
Solution Approach 1:
The calibration tool includes predetermined positions that are pre-defined in the control unit before any crash or design change occurs. These predetermined positions serve as reference points that enable rapid recalibration by simply comparing current sensor readings against the pre-stored reference data, eliminating the need for time-consuming manual recalibration procedures.
Solution Approach 2:
The calibration process involves changing the operational parameters of the robot arm by moving it to specific predetermined positions and orientations. By systematically varying the arm's position parameters and comparing sensor readings against reference values, the system efficiently determines new TCP coordinates without requiring extensive recalibration time.
3Manufacturing precision
If complex calibration procedures are implemented, then alignment precision is improved, but ease of operation deteriorates
Solution Approach 1:
The control unit automatically executes the calibration procedure without requiring complex manual operations. The system self-calibrates by autonomously moving the robot arm through predetermined positions, collecting sensor data, and calculating new TCP coordinates, reducing the operator's role to simply initiating the process and retrieving results.
Solution Approach 2:
All calibration parameters, predetermined positions, and calculation algorithms are pre-configured in the control unit. This preliminary setup eliminates the need for operators to perform complex adjustments during calibration - they simply need to attach the calibration tool and start the automated process, significantly simplifying operation while maintaining high precision.
Data Source
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AI summary
The invention relates to a method for precision alignment of a tool (1) attachable to an arm end (2) of a robot arm (3) of a manufacturing robot (4), wherein a current tool center point (TCP) for the tool (1) is determined by using a calibration device (5) comprising a target (6) mounted on a fixed base (7) and a calibration tool (8) with a plurality of pointers (9), the tip (10) of which each forms its own tool center point, which is mounted on the arm end (2). Furthermore the method relates to a calibration device (5) and a manufacturing robot (4).