Visual Guidance System for Robot Manipulator Calibration
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Solution Overview
Problem
Current systems for industrial robot calibration are time-consuming, require skilled personnel, and limit flexibility and productivity due to the need for recalibration when switching between different work pieces, often involving complex mathematical formulas and lengthy procedures.
Innovation Solution
A visual guidance and recognition system that uses a servo actuated manipulator with a camera to acquire two-dimensional images of work pieces, learns reference pieces, and adjusts the manipulator's position without the need for calibration targets, allowing for quick adaptation to different work pieces by calculating dimensional data offsets and moving the manipulator to align accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional calibration systems are used to improve manufacturing precision, then positioning accuracy is improved, but setup time and complexity increase significantly
Solution Approach 1:
The system performs preliminary calibration by capturing images of the workpiece at multiple predetermined positions before actual manufacturing. These pre-captured images are stored and used for subsequent positioning operations, eliminating the need for repeated calibration procedures and significantly reducing setup time while maintaining positioning accuracy.
Solution Approach 2:
The system creates a digital copy of the workpiece by capturing images at multiple positions and reconstructing a three-dimensional model. This digital replica is stored in memory and used for positioning calculations, replacing the need for physical calibration targets and repeated manual calibration processes.
2Manufacturing precision
If traditional calibration systems are used to improve manufacturing precision, then positioning accuracy is improved, but system complexity increases
Solution Approach 1:
The system replaces complex mechanical calibration procedures with an optical imaging system. Instead of using physical calibration targets, rulers, or manual measurement devices, the system uses a camera to capture images and automatically compute positioning data through image processing and three-dimensional reconstruction algorithms.
Solution Approach 2:
The system performs self-calibration by automatically capturing images, processing them through the reconstruction algorithm, and generating positioning data without requiring external calibration equipment or skilled operators. The manipulator and camera system calibrates itself through the imaging and computation process.
3Manufacturing precision
If recalibration is performed for each workpiece type to maintain positioning accuracy, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The system performs preliminary image capture and three-dimensional reconstruction for each workpiece type once, storing the results in memory. When producing multiple units of the same workpiece type, the pre-stored data is reused without requiring recalibration, enabling rapid production while maintaining positioning accuracy.
Solution Approach 2:
The system creates a universal positioning method that works for any workpiece type. By capturing images at multiple predetermined positions and reconstructing three-dimensional models, the system can handle diverse workpiece geometries with a single approach, eliminating the need for different calibration procedures for different workpiece types.
4Manufacturing precision
If skilled personnel are used for calibration to improve positioning accuracy, then manufacturing precision is improved, but operational complexity increases
Solution Approach 1:
The system performs automatic self-calibration through image capture and processing. The manipulator positions the camera, captures images, and the system automatically reconstructs the three-dimensional model and computes positioning data without requiring skilled operators to perform manual measurements or adjustments.
Solution Approach 2:
The system replaces skilled manual calibration operations with automated imaging and computation. Instead of relying on operators with specialized skills to perform complex calibration procedures, the system uses a camera-based optical system and algorithmic processing to automatically achieve accurate positioning.
Data Source
AI summary
Disclosed herein are embodiments and methods of a visual guidance and recognition system requiring no calibration. One embodiment of the system comprises a servo actuated manipulator configured to perform a function, a camera mounted on the face plate of the manipulator, and a recognition controller configured to acquire a two dimensional image of the work piece. The manipulator controller is configured to receive and store the face plate position at a distance “A” between the reference work piece and the manipulator along an axis of the reference work piece when the reference work piece is in the camera's region of interest. The recognition controller is configured to learn the work piece from the image and the distance “A”. During operation, a work piece is recognized with the system, and the manipulator is accurately positioned with respect to the work piece so that the manipulator can accurately perform its function.