Robotic Tool Center Point Calibration via Vision System
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Solution Overview
Problem
Current methods for determining and calibrating the tool center point (TCP) of robotic tools are inaccurate, time-consuming, and require skilled technicians, with significant downtime and increased equipment costs due to reliance on manual calibration and ambient light, and dedicated IO systems.
Innovation Solution
The iRTorchMate system uses an iRVision™ system to optically calibrate the tool center point by generating images of the robotic tool, calculating its configuration, and updating the user tool position in real-time, eliminating the need for manual calibration and dedicated IO systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration methods are used to determine tool center point, then calibration accuracy can be achieved, but calibration time is excessive (approximately 15 minutes) and requires skilled technicians
Solution Approach 1:
The patent replaces manual mechanical calibration methods with an automated vision-based system. The iRVision system uses optical sensors and image processing to automatically detect tool features and calculate tool center point, eliminating the need for manual measurement and calculation while maintaining high accuracy.
Solution Approach 2:
The system enables self-calibration by automatically detecting tool features through vision sensors and computing tool center point without requiring skilled technicians. The robot can perform its own tool calibration by processing images of calibration targets or tool features, making the process autonomous and eliminating dependency on expert operators.
2Productivity
If pre-specified tool center points are used for robotic tools, then setup time is reduced, but accuracy deteriorates due to variations between individual tools and changes from crashes or wear
Solution Approach 1:
The system dynamically updates tool center point parameters based on real-time vision measurement data. Instead of using fixed pre-specified values, the system continuously monitors tool position and orientation through optical sensors and adjusts the tool center point coordinates to reflect actual tool conditions, accounting for wear, crashes, or reconfiguration.
Solution Approach 2:
The vision system provides continuous feedback on tool position and orientation by capturing images and comparing them against expected configurations. This feedback loop allows the system to detect deviations from the programmed tool center point and automatically correct or alert operators, ensuring sustained accuracy throughout operation.
3Ease of operation
If dedicated IO systems are used for calibration, then calibration functionality is provided, but equipment cost increases
Solution Approach 1:
The patent integrates calibration functionality into the existing vision system that is already used for other inspection and guidance tasks. The same optical sensors, cameras, and image processing algorithms serve both general vision guidance functions and specific tool center point calibration, eliminating the need for separate dedicated calibration hardware and reducing overall system cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for rapid and accurate calibration of the tool center point, reducing calibration time to seconds and eliminating the need for skilled technicians, while supporting various robotic tools without additional hardware costs.
Implementation Method 1
an image generating device disposed in the housing and positioned to generate an image of the robotic tool received through the aperture of the housing
Implementation Method 2
a light source disposed in the housing to backlight the robotic tool received through the aperture of the housing
Data Source
AI summary
A system for calibrating a robotic tool includes a housing including an aperture for receiving the robotic tool, an image generating device disposed in the housing and positioned to generate an image of the robotic tool received through the aperture of the housing, wherein the image generating device generates an image signal representing the image of the robotic tool, a light source disposed in the housing to backlight the robotic tool received through the aperture of the housing, and a processor responsive to the image signal for calculating and monitoring a configuration of the robotic tool.