Absolute Positioning Accuracy Improvement in an Industrial Robot

Modeling and Parameter Identification of a 3D Measurement System Based on Redundant Laser Range Sensors for Industrial Robots

The low absolute positioning accuracy of industrial robots is one of the bottlenecks preventing industrial robots from precision applications. Kinematic calibration is the main way to improve the absolute positioning accuracy of industrial robots, which greatly relies on three-dimensional (3D) measurement instruments, including laser trackers and pull rope mechanisms. These instruments are costly, and their required intervisibility space is large. In this paper, a precision 3D measurement instrument integrating multiple laser range sensors is designed, which fuses the information of multiple redundant laser range sensors to obtain the coordinates of a 3D position. An identification model of laser beam position and orientation parameters based on redundant distance information and standard spherical constraint is then developed to reduce the requirement for the assembly accuracy of laser range sensors. A hybrid identification algorithm of PSO-LM (particle swarm optimization Levenberg Marquardt) is designed to solve the high-order nonlinear problem of the identification model, where PSO is used for initial value identification, and LM is used for final value identification. Experiments of identification of position and orientation, verifications of the measuring accuracy, and the calibration of industrial robots are conducted, which show the effectiveness of the proposed 3D measurement instrument and identification methods. Moreover, the proposed instrument is small in size and can be used in narrow industrial sites.

High-precision magnetorheological finishing based on robot by measuring and compensating trajectory error

The 6-DOF industrial robot has wide application prospects in the field of optical manufacturing because of its high degrees of freedom, low cost, and high space utilisation. However, the low trajectory accuracy of robots will affect the manufacturing accuracy of optical components when the robots and magnetorheological finishing (MRF) are combined. In this study, aiming at the problem of the diversity of trajectory error sources of robot-MRF, a continuous high-precision spatial dynamic trajectory error measurement system was established to measure the trajectory error accurately, and a step-by-step and multistage iterations trajectory error compensation method based on spatial similarity was established to obtain a high-precision trajectory. The experimental results show that compared with the common model calibration method and general non-model calibration method, this trajectory error compensation method can achieve accurate compensation of the trajectory error of the robot-MRF, and the trajectory accuracy of the Z-axis is improved from PV > 0.2 mm to PV < 0.1 mm. Furthermore, the finishing accuracy of the plane mirror from 0.066λ to 0.016λ RMS and the finishing accuracy of the spherical mirror from 0.184λ RMS to 0.013λ RMS using the compensated robot-MRF prove that the robot-MRF has the ability of high-precision polishing. This promotes the application of industrial robots in the field of optical manufacturing and lays the foundation for intelligent optical manufacturing.

Deep Q-Learning in Robotics: Improvement of Accuracy and Repeatability

Recent industrial robotics covers a broad part of the manufacturing spectrum and other human everyday life applications; the performance of these devices has become increasingly important. Positioning accuracy and repeatability, as well as operating speed, are essential in any industrial robotics application. Robot positioning errors are complex due to the extensive combination of their sources and cannot be compensated for using conventional methods. Some robot positioning errors can be compensated for only using machine learning (ML) procedures. Reinforced machine learning increases the robot’s positioning accuracy and expands its implementation capabilities. The provided methodology presents an easy and focused approach for industrial in situ robot position adjustment in real-time during production setup or readjustment cases. The scientific value of this approach is a methodology using an ML procedure without huge external datasets for the procedure and extensive computing facilities. This paper presents a deep q-learning algorithm applied to improve the positioning accuracy of an articulated KUKA youBot robot during operation. A significant improvement of the positioning accuracy was achieved approximately after 260 iterations in the online mode and initial simulation of the ML procedure.

Fast Kinematic Re-Calibration for Industrial Robot Arms

Accurate kinematic modelling is pivotal in the safe and reliable execution of both contact and non-contact robotic applications. The kinematic models provided by robot manufacturers are valid only under ideal conditions and it is necessary to account for the manufacturing errors, particularly the joint offsets introduced during the assembling stages, which is identified as the underlying problem for position inaccuracy in more than 90% of the situations. This work was motivated by a very practical need, namely the discrepancy in terms of end-effector kinematics as computed by factory-calibrated internal controller and the nominal kinematic model as per robot datasheet. Even though the problem of robot calibration is not new, the focus is generally on the deployment of external measurement devices (for open loop calibration) or mechanical fixtures (for closed loop calibration). On the other hand, we use the factory-calibrated controller as an 'oracle' for our fast-recalibration approach. This allows extracting calibrated intrinsic parameters (e.g., link lengths) otherwise not directly available from the 'oracle', for use in ad-hoc control strategies. In this process, we minimize the kinematic mismatch between the ideal and the factory-calibrated robot models for a Kinova Gen3 ultra-lightweight robot by compensating for the joint zero position error and the possible variations in the link lengths. Experimental analysis has been presented to validate the proposed method, followed by the error comparison between the calibrated and un-calibrated models over training and test sets.

Observation and analysis of diving beetle movements while swimming

The fast swimming speed, flexible cornering, and high propulsion efficiency of diving beetles are primarily achieved by their two powerful hind legs. Unlike other aquatic organisms, such as turtle, jellyfish, fish and frog et al., the diving beetle could complete retreating motion without turning around, and the turning radius is small for this kind of propulsion mode. However, most bionic vehicles have not contained these advantages, the study about this propulsion method is useful for the design of bionic robots. In this paper, the swimming videos of the diving beetle, including forwarding, turning and retreating, were captured by two synchronized high-speed cameras, and were analyzed via SIMI Motion. The analysis results revealed that the swimming speed initially increased quickly to a maximum at 60% of the power stroke, and then decreased. During the power stroke, the diving beetle stretched its tibias and tarsi, the bristles on both sides of which were shaped like paddles, to maximize the cross-sectional areas against the water to achieve the maximum thrust. During the recovery stroke, the diving beetle rotated its tarsi and folded the bristles to minimize the cross-sectional areas to reduce the drag force. For one turning motion (turn right about 90 degrees), it takes only one motion cycle for the diving beetle to complete it. During the retreating motion, the average acceleration was close to 9.8 m/s² in the first 25 ms. Finally, based on the diving beetle's hind-leg movement pattern, a kinematic model was constructed, and according to this model and the motion data of the joint angles, the motion trajectories of the hind legs were obtained by using MATLAB. Since the advantages of this propulsion method, it may become a new bionic propulsion method, and the motion data and kinematic model of the hind legs will be helpful in the design of bionic underwater unmanned vehicles.

Industrial Robot Positioning Performance Measured on Inclined and Parallel Planes by Double Ballbar

Renishaw Ballbar QC20–W is primarily intended for diagnostics of CNC machine tools, but it is also used in connection with industrial robots. In the case of standard measurement, when the measuring plane is parallel to the robot base, not all robot joints move. The purpose of the experiments of the present article was to verify the hypothesis of the motion of all the robot joints when the desired circular path is placed on an inclined plane. In the first part of the conducted experiments is established hypothesis is confirmed, through positional analysis on a simulation model of the robot. They are then carried out practical measurements being evaluated the influence of individual robot joints to deform the circular path, shown as a polar graph. As a result, it is found that in the case of the robot used, changing the configuration of the robot arm has the greatest effect on changing the shape of the polar graph.

Improving the measuring length accuracy of articulated arm coordinate measuring machine using artificial neural network

A new method for further improving the measuring length accuracy of the articulated arm coordinate measuring machine (AACMM) is proposed. The detailed procedure of the proposed method involves kinematic error calibration with the Levenberg-Marquardt algorithm and then non-kinematic error (such as link deflection, thermal errors, and error motions of the rotation shaft) compensation with a back-propagation neural network optimized by the mind evolutionary algorithm. In order to verify the effectiveness and correctness of the proposed method, the simulation and experiment were carried out on an AACMM. The simulated and experimental results demonstrate that the measuring length accuracy of the AACMM is improved significantly after kinematic error calibration and non-kinematic error compensation, confirming the effectiveness and correctness of the proposed method.

New Method and Portable Measurement Device for the Calibration of Industrial Robots

This paper presents an automated calibration method for industrial robots, based on the use of (1) a novel, low-cost, wireless, 3D measuring device mounted on the robot end-effector and (2) a portable 3D ball artifact fixed with respect to the robot base. The new device, called TriCal, is essentially a fixture holding three digital indicators (plunger style), the axes of which are orthogonal and intersect at one point, considered to be the robot tool center point (TCP). The artifact contains four 1-inch datum balls, each mounted on a stem, with precisely known relative positions measured on a Coordinate Measuring Machine (CMM). The measurement procedure with the TriCal is fully automated and consists of the robot moving its end-effector in such as a way as to perfectly align its TCP with the center of each of the four datum balls, with multiple end-effector orientations. The calibration method and hardware were tested on a six-axis industrial robot (KUKA KR6 R700 sixx). The calibration model included all kinematic and joint stiffness parameters, which were identified using the least-squares method. The efficiency of the new calibration system was validated by measuring the accuracy of the robot after calibration in 500 nearly random end-effector poses using a laser tracker. The same validation was performed after the robot was calibrated using measurements from the laser tracker only. Results show that both measurement methods lead to similar accuracy improvements, with the TriCal yielding maximum position errors of 0.624 mm and mean position errors of 0.326 mm.