Robotic Welding Tool Center Point Calibration via Optical Triangulation
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Solution Overview
Problem
Conventional robotic welding systems require manual and time-consuming calibration of the tool center point (TCP) in 3D space, which is prone to operator error and inefficiency.
Innovation Solution
The method involves using a controller with image sensors to identify and calibrate the tool center point by defining a longitudinal axis of a protrusion from the weldhead, triangulating its location in 3D space, and generating TCP calibration values, thereby automating the calibration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration of TCP is performed, then operator control is maintained, but calibration time increases and operator error risk increases
Solution Approach 1:
The patent replaces manual mechanical calibration operations with an automated optical measurement system. Image sensors capture images of a calibration object, and a controller automatically processes these images to determine TCP coordinates, eliminating the need for manual measurement tools and operations while improving both speed and accuracy.
Solution Approach 2:
The patent uses image sensors to create optical copies (images) of the calibration object and its features. These image copies are then processed by the controller to extract geometric information and calculate TCP position, replacing direct physical measurement with indirect optical replication and digital analysis.
2Reliability
If manual calibration is used, then system complexity remains low, but operator error increases and reliability decreases
Solution Approach 1:
The patent replaces error-prone manual operations with an automated system comprising image sensors and a controller. This substitution eliminates human factors such as reading errors, calculation mistakes, and inconsistent techniques, significantly improving calibration reliability despite the increased system complexity.
Solution Approach 2:
The calibration system performs self-measurement and self-calculation functions. The image sensors automatically capture calibration object features, the controller processes these images to extract geometric data, and the system autonomously computes TCP coordinates without requiring operator intervention in the measurement and calculation processes.
3Productivity
If automated image-based calibration is implemented, then calibration speed increases, but system complexity increases
Solution Approach 1:
The patent replaces slow manual calibration procedures with automated optical imaging and digital image processing. Multiple images can be captured rapidly, and the controller automatically processes these images to determine TCP position, dramatically increasing calibration speed while accepting the addition of image sensors and processing capabilities.
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 reduces manual intervention, minimizes operator error, and enhances the accuracy and speed of TCP calibration, improving the precision and reliability of robotic welding operations.
Implementation Method 1
identifying by a controller a location in three-dimensional (3D) space of the weldhead based on the protrusion identified in the plurality of images and the defined longitudinal axis of the protrusion
Data Source
AI summary
Disclosed are systems, methods, and apparatuses, including computer programs encoded on computer storage media, for operation of a robotic welding system. In one aspect, a method for calibrating a tool center point (TCP) of the robotic welding system includes identifying, based on multiple images, a location of a tip of a protrusion extending from the weldhead. Each image of the multiple images including at least a portion of the protrusion extending from a tip of the weldhead. The tip of the weldhead is associated with a first frame of reference. The method also includes determining, based on the location of the terminal end of the protrusion, a second frame of reference that is offset from the first frame of reference. The method further includes generating one or more TCP calibration values based on the second frame of reference. Other aspects and features are also claimed and described.