The present invention relates to a method for calibration of an industrial robot according to the preamble of claim 1.
An industrial robot can be viewed as a cinematic chain of sections movably connected to each other about a plurality of rotational axis. The first section in the chain is the base of the robot and the last section usually constitutes a tool attachment. The axis are numbered after their position in the cinematic chain, i.e. the first axis in the chain is denoted the first axis, the next axis is denoted the second axis and so on. For the possibility to determine the position of the robot, each axis usually is provided with an angle-measuring device in the form of an encoder or a resolver indicating the position of the axis relative to a zero position. Before an industrial robot can be used it must be calibrated, which means that each of the angle-measuring devices is calibrated with reference to the zero position. The robot is calibrated in the production plant before it is delivered and sometimes on site before being set to work. Thereafter, the robot is calibrated after larger repairs such as motor or arm changes or after collisions. During calibration the correct cinematic position, denoted the home position, of the robot is identified. When the robot is in its home position all axes are in their zero position and thus the angular values from the encoders/resolvers are zero or a reference value.
In the prior art it is known to use an inclinometer, or some other type of instrument for measuring the inclination, to calibrate the robot. An inclinometer measures the angle between an object and the vertical line and is, for example, an electronic spirit level. A calibration device including at least one inclinometer is placed on a plane of reference on one of the sections, and generates a signal, which is a measure of the angle between the plane of reference of the section and the vertical line. Thereafter, the axis is moved in dependence of the generated signal until it has a predetermined angle relative to the vertical line. The other axes are calibrated in the same way by means of further reference planes. Such a calibration method is for example disclosed in the patent document U.S. Pat. No. 5,239,855 and in the international patent application WO02/084216.
In order to obtain a high accuracy of the calibration, the planes of reference must be accurately machined to a high degree of flatness. A disadvantage with this method is that the accuracy of the calibration depends on the accuracy of the planes of reference and the mounting of the calibration device on the plane of reference. For example waste material on the reference surface or imperfections in the machining of the surface may cause an angular error leading to a calibration error. For calibration with the calibration device mounted on the tool attachment there is a large influence on the calibration result due to the small reference surface on the edge of the tool flange. For this mounting position there is also a large influence of the housing of the calibration device on the calibration, which leads to differences between production and field calibrations.
The object of the present invention is to provide an improved calibration method, which minimizes the influence from the mounting of the calibration device on the robot.
This object is achieved by a method as defined in claim 1. According to the invention an axis is calibrated based on angular measurements in two or more calibration positions. In the following the axis to be calibrated is called the calibration axis. The vertical line is defined as the line of gravity. The reference direction is either the direction of a fixed reference or the direction of an axis earlier in the cinematic chain. The measuring axis is selected as one of the robot axes and it is used for rotating the robot between the calibration positions during calibration of the calibration axis. The measuring axis should be selected such that the direction of the measuring axis reflects the misalignment of the calibration axis. This method differs from the previously described prior art method, in that the axis is calibrated based on the relation between an axis and the vertical line, instead of based on the relation between the mounting plane of the measuring member and the vertical line. Tanks to the fact that the calibration is performed based on the relation between an axis and the vertical line, instead of based on the relation between the mounting plane of the measuring member and the vertical line; the mounting error of the measuring member is eliminated.
The invention minimizes the mechanical influence on the calibration result. This is needed in order to facilitate a 100% repeatable robot position in field with the goal to eliminate program updates and to keep absolute accuracy performance. Mechanical influence can be divided into two groups. The first group will cause errors between the correct kinematic robot position and the actual robot position. This deviation is built into the robot, for example due to manufacturing tolerances, and will be repeated every calibration. The result of having cinematic errors is that the robot behavior will not be as correct as possible. The second group of mechanical influence will cause errors related to different sets of calibration equipment. Differences in this area will cause errors in the robot positioning when updating the robot in field after repair. The method according to the invention minimizes the influence on the calibration result for the first as well as the second group of mechanical influence.
A further advantage with the invention is that the reference planes used in the prior art for calibration of the third and forth axis can be removed since it doesn't have any function with the method according to the invention. Another advantage gained is that the tolerance for manufacturing the reference plane and the calibration equipment are reduced. Another advantage with the invention is that the calibration of the fifth axis can be made independent of the position of the third axis. The invention also facilitates the calibration of axes three, four, five and six without dismounting the angle measuring member and by this not introducing other measuring error.
The method according to the invention is applicable on any calibration equipment using a water leveling device, electronic as well as mechanical.
According to an embodiment of the invention the method comprises calculating the direction of the measuring axis based on said angular values, identifying the misalignment of the calibration axis based on the direction of the measuring axis and on basis thereof calibrating the calibration axis. The measuring axis should be selected such that the direction of the measuring axis reflects of the misalignment of the calibration axis. The calibration positions are selected so that it is possible to calculate the direction of the measuring axis based on the angular measurements in the calibration positions. Accordingly, it is possible to calculate the misalignment of the calibration axis based on the measured angular values.
According to an embodiment of the invention two calibration positions are selected and the direction of the measuring axis is calculated as the difference between the angular values divided by two. The two calibration positions are selected so that the measuring axis is rotated 180 degrees between the two positions. This is advantageous since it facilitates the mathematics needed for the calibration. However, the invention can be used for any rotation when combined with transformation onto the plane of calculation. p According to an embodiment of the invention the method comprises calculating the measuring error of the angular measuring member based on said angular values. The measuring error is the sum of the mounting error and the sensor offset. The calibration positions are selected such that the measuring error depends on the relation between the angular values. Thus, it is possible to calculate the measuring error based on the angular measurements in the calibration positions.
According to an embodiment of the invention two calibration positions are selected and the measuring error of the angular measuring member is calculated as the sum of the angular values divided by two. The measuring axis is rotated 180 degrees between the two positions. This is advantageous since it facilitates the mathematics needed for the calibration. However, the invention can be used for any rotation when combined with transformation onto the plane of calculation.
According to an embodiment of the invention the method comprises selecting a second calibration axis, selecting a reference axis to the second calibration axis, moving the robot to its home position, and calibrating the second calibration axis based on said calculated measuring error and the reference direction of the second calibration axis. This embodiment eliminates the need of a separate reference plane for the third axis and all calibration can be made without moving the angular measuring member.
According to an embodiment of the invention the method comprises selecting a second calibration axis, selecting a reference axis to the second calibration axis, moving the robot to a new calibration position, reading a new angular value from the angle measuring member in said new calibration position, and calibrating the second calibration axis based on the new angular value, said calculated measuring error and the reference direction of the second calibration axis.
According to an embodiment of the invention the calibration positions are selected such that, provided that the angle measuring member is ideal and correctly mounted on the robot and that the robot is an ideal robot, the angle measuring member should produce the same angular value, or angular values that differs with a predefined amount, in the calibration positions. If there is a misalignment of the calibration axis, the position of the angle measuring member, and thus the angle measurement, will change between the calibration positions, otherwise the position of the angle measuring member will remain the same.
According to an embodiment of the invention the robot comprises three successive axes including a rear, an intermediate and a fore axes, wherein the intermediate axis is arranged non-parallel to the rear and fore axis, and the method comprises selecting the intermediate axis as the calibration axis, the fore axis as the measuring axis, and the rear axis as the reference direction, moving the robot to a first calibration position, reading a first angular value from the angle measuring member, moving the robot to a second calibration position, including rotating it about the fore axis, reading a second angular value from the angle measuring member, and calibrating the intermediate axis based on said first and second angular value and the reference direction. For example, the robot includes six axes and said rear axis corresponds to the fourth axis of the six-axes robot, said intermediate axis corresponds to the fifth axis of the six-axes robot, and said fore axis corresponds to the sixth axis of the six-axes robot.
According to another embodiment of the invention the robot comprises three successive axes including a rear, an intermediate and a fore axes, wherein the intermediate axis is arranged non-parallel to the rear and fore axis, and the method comprises selecting the intermediate and rear axis as the calibration axes and the fore axis as the measuring axis, moving the robot to a first calibration position, reading a first angular value from the angle measuring member, moving the robot to a second calibration position, including rotating the robot about the fore axis, reading a second angular value from the angle measuring member, and calibrating the rear and intermediate axes based on said first and second angular value, and the measured reference direction. For example, the robot includes six axes and said rear axis corresponds to the third axis of the six-axes robot, said intermediate axis corresponds to the fourth axis of the six-axes robot, and said fore axis corresponds to the fifth axis of the six-axes robot. According to this embodiment of the invention the rear, and intermediate axis are calibrated based on only two angular measurements. This embodiment and the previous can be combined for all three calibrations without dismounting the angular measuring member.
According to an embodiment of the invention robot comprises a tool attachment mounted rotatable about an tool axis and the angular measuring member is mounted on the tool attachment, wherein the method comprises before reading at least some of the angular values moving the robot about the tool axis so that the angular measuring member is brought into its measuring position. This embodiment makes it possible to carry out all necessary measurements without having to dismount the angular measuring member and reorientate it between the measurements.
According to an aspect of the invention, the object is achieved by a computer program directly loadable into the internal memory of a computer or a processor, comprising software code portions for performing the steps of the method according to the invention, when said program is run on a computer. The computer program is for example provided on a computer readable medium or through a network.
According to another aspect of the invention, the object is achieved by a computer readable medium having a program recorded thereon, when the program is to make a computer perform the steps of the method according to the invention, and said program is run on the computer.
Another object of the present invention is to provide a system for automatic calibration of an industrial robot, which minimizes the influence from the mounting of the calibration equipment on the robot. This object is achieved by a system defined by claim 24. It is easy to realize that the method according to the invention, as defined in the appending set of method claims, is suitable for being executed by an automatic calibration system. Even though not explicitly expressed in the claims, the invention covers a system adapted for carrying out the method according to the appended method claims.
A calibration method according to the invention is useful for calibration of an industrial robot having six axes, as well as for calibration of a robot having any other number of axes.
The invention will now be explained more closely by the description of different embodiments of the invention and with reference to the appended figures.
a shows a further example of a calibration position in a side view.
b shows an example of three different calibration positions seen from above.
When the robot is in its home position, as shown in
In
Wyler sensor is suitable as angular measuring member. The basic principals of the method according to the invention will now be discussed in relation to
Further a reference axis is selected, which is used as a reference during the calibration. Different reference axis can be used during the calibration. The reference axis is either a fixed reference, for example the normal to a reference plane of the robot, or one of the robot axes. For example axis A1 or A4 is suitable as the reference axis. The calibration axis should be positioned after the reference axis in the kinematic chain of the robot. The direction of the measuring axis relative to the direction of the reference axis is measured and used for providing the calibration axis with a calibration position. In order to measure the direction of the measuring axis, it is rotated between at least two angels and the angle measuring device is read for those angels. The measuring axis should be selected such that the direction of the measuring axis reflects of the misalignment of the calibration axis.
During the calibration, the calibration axis has to be positioned in a direction that differs from the vertical line. The best accuracy is obtained when the calibration axis is perpendicular to the vertical line, but this is not necessary. In the example shown in
The angular positions used for the calibration are selected such that the angle measuring member 7 member is ideal and should provide the same angular value in both positions if the measuring member is correctly mounted on the robot and if the calibration axis is correctly positioned. As shown in
In the following it will be shown by way of an example how the general principle explained above can be used for calibration of a robot having six axes. However, the invention is not limited to a six axes robot, in the opposite the general method is also applicable for robots having various numbers of axes.
It is possible to calibrate all axes, except axis A6, with the method according to the invention, but is not always practical. Preferably, calibrations of axis A1, A2 and A6 are performed by any of the prior art calibration methods known as such. Even though it for example is possible to calibrate axis A2 with the method according to the invention, it is not practical since it requires that axis A1 is rotated 180 degrees and the space needed to performing this rotation is normally not available. During calibration of the first axis A1 reference angles from the base are read and stored in the control system of the robot. Preferably, the calculations performed during the entire calibration are performed in the control system of the robot. Thereafter, the control system orders the axes being calibrated to move in dependence of the calculated adjustments value until the axis ends up in its predetermined zero position. As an alternative the identified calibration angles can be used directly without moving the robot.
During calibration of axes A3, A4, A5 and A6 the angular measuring member 7 is attached to the tool attachment 6. The method according to an embodiment of the invention will be described with reference to
As seen from
Calibration of axis A3 and A4 will now be discussed in relation to
The average of the readings (c−d)/2, wherein d is measured turned 180 degrees, shall be equal to the reference value measured on the base, i.e. the base reference of the robot. The difference between the base reference and the average of the reading is the misalignment of axis A4. This information is used for correction of axis A4. Accordingly, axis A4 is adjusted based on the difference between the base reference and the average reading, i.e. [base ref−(c−d)/2]. After repositioning for reading c, axis A4 of the robot is moved to the value [c+base ref−(c−d)/2].
The misalignment in the mounting of the angular measuring member on the tool plate is calculated as the sum of the readings c and d divided by 2, i.e. [(c+d)/2], wherein d is measured turned 180 degrees. Axis A4, axis A5 and axis A6 are rotated back to the home position. Axis A3 is then calibrated based on the calculated misalignment of the angular measuring member, i.e. based on [(c+d)/2]. Axis A3 is moved to a new value, which is calculated as the base reference value, adjusted for the misalignment of the angular measuring member [(c+d)/2], and is now corrected. Thus, axes A3, A4 and A5 have been calibrated based on only four measurements.
The method according to the invention is suitable for being automatically executed by a computer program having instructions corresponding to the steps in the inventive method when run on a processor unit, for example in the control system of the robot. The operator mounts the angle measuring member on the tool plate. The software produces control signals moving the robot to the calibration positions. The control system receives measurement signals from the angular measuring member and calculates the adjustments necessary in order to calibrate the axis. The software produces control signals to the robot based on the calculated adjustments. The robot is moved in accordance with the received control signals until the axis is in its correct position. The control system of the robot comprises necessary equipments, such as a processor, memory, and other units for running the software, which performs the calibration.
There are many possibilities to implement the invention for calibration of the axes A3, A4, A5. For example axes A4 and A5 can be calculated by rotating axis A6 between three calibration positions V1, V2 and V3, as shown in
The present invention is not limited to the embodiments disclosed but may be varied and modified within the scope of the following claims. For example it should be noted that the steps of the invention could be performed in a sequence different from them disclosed in the previous embodiment examples. In particular the sequence of the steps in the claim could as well be performed in another order to achieve the object of the invention. In the previously described example, the sequence in which the axes are calibrated is A5, A4, A3. However, it is also possible to calibrate the axes for example in the sequence A4, A5, A3. In order to achieve a high accuracy axis A5 should preferably be calibrated before axis A3. It is also possible to perform all the measuring before executing the calibration of the axis.
Number | Date | Country | Kind |
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0402750-4 | Nov 2004 | SE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/SE05/01578 | 10/21/2005 | WO | 5/10/2007 |