Robot Calibration via Vision Sensor Coordinate Correction
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Solution Overview
Problem
Current robot programming methods, particularly online teaching, are time-consuming and lack accuracy when dealing with complex workpieces, and as manufacturing requirements become more stringent, there is a need for a fast and accurate calibration method to address high precision in robot operations.
Innovation Solution
A calibrating system and method that uses sensors and sensor carriers to measure and correct actual object coordinates, integrating with offline programming to ensure precise alignment and operation of robots and tools, utilizing a setting module to determine sensor types based on object shapes, a comparison module to calculate errors, and a control module to drive operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If online teaching is used to program robot operations, then the robot can be taught to follow predetermined paths, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent uses vision sensors to capture images of the workpiece and creates a digital model (copy) of the workpiece geometry. This digital model is then used for path planning and robot control, eliminating the need for time-consuming online teaching while maintaining high path accuracy through image-based coordinate extraction and transformation.
2Loss of time
If offline programming with virtual-real integration is used, then programming time is reduced, but very high accuracy requirements are imposed on actual and relative coordinates of robots, tools, and workpieces
Solution Approach 1:
The patent employs vision sensors to capture actual workpiece images and compares them with the digital model, performing coordinate transformations to compensate for positioning deviations. This feedback mechanism corrects coordinate errors in real-time, achieving high manufacturing precision without requiring extremely tight initial coordinate tolerances.
3Adaptability or versatility
If robot systems are designed to support a wider variety of workpieces and tools, then versatility is improved, but calibration complexity and time requirements increase
Solution Approach 1:
The patent implements a universal vision-based calibration system that can handle various workpiece geometries and tool types through image processing and automatic feature recognition. The system uses a standardized calibration workflow with configurable parameters, allowing it to adapt to different applications without requiring complex specialized calibration procedures for each workpiece-tool combination.
Data Source
AI summary
A calibrating method is provided including the following steps. A type of a first sensor and a type of a first sensor carrier are determined according to an external shape of a first object. The first sensor is carried by the first sensor carrier, and a relative coordinate of the first object is measured by the first sensor. The relative coordinate of the first object is compared with a predetermined coordinate of the first object to obtain a first object coordinate error, and the first object coordinate error is corrected. After the first object coordinate error is corrected, the first object is driven to perform an operation on a second object or the second object is driven to perform the operation on the first object. A calibrating system is also provided.