Robotic End Effector Calibration via Offset Tool Docking
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Solution Overview
Problem
Inaccurate positioning of robotic end effectors in medical testing and processing systems leads to collisions and unwanted spillage of specimens, highlighting the need for improved calibration methods to determine the positional offset between the end effector and position sensors in robotic systems.
Innovation Solution
A calibration system and method using a teach target, offset tool, and offset target to measure positional offsets between the end effector and position sensor, involving a docking mechanism that allows for precise determination of the end effector's position relative to the position sensor, enabling accurate calibration in X, Y, and Z coordinates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used, then the calibration process can be completed, but positioning accuracy is insufficient leading to collisions and spillage
Solution Approach 1:
The patent introduces a calibration target with known geometric features as an intermediary object between the position sensor and the end effector. This calibration target serves as a mediator that enables precise measurement of the positional offset, thereby improving positioning accuracy without directly modifying the end effector or sensor systems.
Solution Approach 2:
The patent replaces traditional mechanical calibration methods with an optical measurement system. The position sensor detects geometric features of the calibration target to determine positional offsets, substituting mechanical contact-based calibration with non-contact optical measurement, thereby achieving higher precision and reliability.
2Measurement precision
If no calibration is performed, then the system can operate quickly, but positioning errors cause collisions and specimen spillage
Solution Approach 1:
The patent performs calibration as a preliminary action before actual sample processing operations. By establishing the positional offset relationship between the end effector and position sensor in advance, the system ensures accurate positioning during subsequent operations without requiring repeated calibration, thus minimizing time loss while maintaining high precision.
Solution Approach 2:
The patent uses a calibration target with known geometric features as a reference copy or model. The position sensor measures this known reference structure to determine the positional offset, creating a mapping relationship that is then applied to subsequent positioning operations, enabling rapid and accurate calibration.
3Measurement precision
If simple positioning methods are used, then the system structure remains simple, but positioning accuracy is insufficient
Solution Approach 1:
The patent introduces a calibration target as an intermediary element that adds minimal complexity to the system. This target with known geometric features serves as a bridge between the position sensor and end effector, enabling precise measurement of positional offsets without requiring complex modifications to the existing robotic system architecture.
Solution Approach 2:
The patent replaces complex mechanical positioning mechanisms with a simpler optical measurement approach. Instead of using complex mechanical linkages or encoders to achieve precise positioning, the system uses a position sensor to optically measure the calibration target and calculate offsets, thereby achieving high precision with reduced mechanical complexity.
Data Source
Figure 1A~1D
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AI summary
Disclosed are systems and apparatus adapted to aid in calibration of an offset position -between a position sensor and an end effector in a processing system. The system includes a robotic component having an end effector and a position sensor coupled thereto, a teach target having a first geometrical feature, and an offset tool adapted to be engaged by the end effector, the offset tool including a first docking feature. The system further includes a moveable offset target having a second docking feature adapted to be engaged by the first docking feature and a second geometrical feature adapted to be sensed by the position sensor. The end effector moves the offset tool to the offset target and docks them. A position of the teach target and the offset target may then be sensed with the position sensor to determine an actual offset of the end effector with respect to the position sensor. Methods of operating the system are provided, as are other aspects.