Robotic Cell Auto-Calibration With Real-Time Pose Compensation
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Solution Overview
Problem
The calibration of robotic assembly systems is a slow, high-precision process that requires expertise and is time-consuming, as it involves coordinating multiple calibration routines for various components within the robotic cell.
Innovation Solution
An auto-calibration system that provides a holistic view of the robotic cell and its working area, using a combination of camera lens calibration, frame registration, end of arm tool contact calibration, and robot pose error compensation, with continuous monitoring and correction to maintain accuracy over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used for robotic assembly systems, then high measurement precision can be achieved, but the calibration process becomes extremely time-consuming and requires expert intervention
Solution Approach 1:
The system performs self-calibration through automated routines that execute without expert intervention. The calibration process is autonomous, with the robotic system adjusting its own parameters based on sensor feedback and coordinate mapping, eliminating the need for manual expert calibration while maintaining high precision
Solution Approach 2:
The calibration system incorporates continuous feedback loops where sensor data from cameras and other detection devices is processed to automatically adjust robotic cell parameters. This closed-loop feedback mechanism enables the system to self-correct and refine calibration accuracy iteratively without requiring external expert input
2Reliability
If multiple separate calibration routines are executed for different robotic components, then comprehensive calibration coverage is achieved, but the overall calibration process becomes complex and time-consuming
Solution Approach 1:
The patent integrates multiple separate calibration routines into a unified holistic calibration process. By combining camera calibration, robotic arm calibration, end effector calibration, and sensor calibration into a single coordinated sequence, the system achieves comprehensive coverage while reducing overall process complexity and execution time
Solution Approach 2:
The calibration system employs a universal coordinate system that serves as a common reference frame for all robotic components and sensors. This multi-functional approach allows the same calibration framework to handle diverse calibration tasks across different components, simplifying the overall process while ensuring complete calibration coverage
3Measurement precision
If expert intervention is required for calibration, then high calibration accuracy can be achieved, but the ease of operation deteriorates and requires specialized knowledge
Solution Approach 1:
The system automatically performs calibration without requiring expert operators. Built-in algorithms process sensor data and adjust calibration parameters autonomously, making the process accessible to operators without specialized calibration knowledge while maintaining high accuracy through automated error correction
Solution Approach 2:
The patent replaces manual expert calibration operations with automated computational algorithms. Instead of relying on human expertise to visually assess and adjust calibration parameters, the system uses computer vision, sensor fusion, and mathematical optimization algorithms to automatically achieve high-precision calibration
4Manufacturing precision
If comprehensive calibration of all robotic cell components is performed, then system accuracy is improved, but the productivity and operational time are reduced due to extensive calibration requirements
Solution Approach 1:
The system performs comprehensive calibration once during initial setup and after major maintenance events, rather than before every operation. This preliminary calibration action establishes a baseline accuracy that enables rapid production operations without repeated full calibration cycles, thereby maintaining high precision while maximizing productivity
Solution Approach 2:
The calibration system operates periodically based on predetermined intervals or triggers (such as after maintenance or when accuracy thresholds are not met), rather than continuously before each task. This periodic calibration approach ensures manufacturing precision is maintained while minimizing interruptions to productive operations
Data Source
AI summary
A robotic cell calibration method comprising a robotic cell system having elements comprising: one or more cameras, one or more sensors, components, and a robotic arm. The method comprises localizing positions of the one or more cameras and components relative to a position of the robotic arm using a common coordinate frame, moving the robotic arm in a movement pattern, and using the cameras and sensors to determine robotic arm position at multiple times during the movement. The method includes identifying a discrepancy in robotic arm position between a predicted position and the determined position in real time, and computing, by an auto-calibrator, a compensation for the identified discrepancy, the auto-calibrator solving for the elements in the robotic cell system as a system. The method includes modifying actions of the robotic arm in real time during the movement based on the compensation.