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Ref - 16 A New Method For Autonomous Robot Calibration
Ref - 16 A New Method For Autonomous Robot Calibration
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the constraint plane in the workspace. Considerations m
include: and Ij = - c H i A & , which determine the network
the robot configurations enabling desirable and safe i=l
touch on the plane; connection weights and input currents respectively based on
* the workspace in which accuracy is critical; the nominal kinematic model and parameters. The Apj is
0 the optimal identification configurations of the robot; thej-th component of kinematic parameters to be identified
the workcell layout and the kind of constraint plane which corresponds to the j-th neuron state. n is the
available. dimension of the vector of kinematic error while m is the
As robot base axes are always set up to align with row number of coefficient matrix H .
some reference planes in the workcell, the assumption The energy function gradient with respect to the i-th
made earlier, in which the constraint plane is aligned with neuron state can be obtained from (9):
the robot base co-ordinates, has practical significance. In
the case that external constraint planes are used, it is also
easy to align the plane with the robot base axis using the (10)
probe and VAL I1 axis motion function. To maximise the The time evolution of neuron states should follow' the
robot movement ranges, it is desirable to have the robot opposite direction of the energy function gradient, so we
touch the constraint planes separately which lie have the neuron circuit dynamics equation:
perpendicular to the robot's base axes. The linear
identification model in this case can be constructed
d ( A p i )- p j ( $ T v A p j
-- +Ii)
according to (7), using the correct component of (2) at each dt j=l
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any direction[l9]. For our application, a special tool
changer was made to hold the probe (Figure 2). The trigger
signal is transmitted as an input to control the robot. The
switch is kept on while the probe is in contact with the
object. The tip-point of the stylus is a ruby ball so that the
contact point from any direction is a constant distance from
the centre of the tip. The stylus has some amount of over-
travel in each direction allowing a certain probing speed.
The data collection procedure written in pseudo-code is as
foollow s:
RecordData(JointValues, CartesianValues);
1 Figure 2. Robot touch constraint plane using a Probe
The robot moves from a start point to a point above the 5 Results for a Puma 560 Robot
constraint plane where its configuration is randomly
generated within the robot movement ranges, from which a
The PUMA 560 robot is a six DOF manipulator with
desirable and safe touch on the constraint plane is ensured.2 six revolute joints. There are in total 24 kinematic
From that point, the robot probes the plane by moving in parameters, using Denavit-Hartenberg (D-H) notation, to
small steps toward the constraint plane until the probe describe the kinemtaic model. In general another six
signal is on. As there is some over-travel of the stylus, the parameters including three each of rotation{roll-pitch-yaw }
stop point is not the point of the first touch due to the and translatjon parameters are needed for TOOL
probing speed. Therefore fine tuning is needed to retract the transfoi-mation.The nominal parameters are listed in Table
first touch point. Whilst still in contact with the plane, the 1. The x-direction offset of the TOOL(probe) is
fine tuning process begins by moving the tip-point away intentionally built to make the robot wrist parameter
from the plane in steps oP one tenth of the probing steps. identifiable. \Ye also noted that there exists dependence
Then the joint values of the robot and the corresponding between the TOOL parameters and the last link parameters.
Cartesian co-ordinates are recorded for post-processing. The To eliminate the parameter redundancy, the TOOL
above process is repeated until the desired number of touch parameters are incorporated into the last link parameters,
points has been reached. regarding the probe as the extended last link of the robot.
The probing and fine tuning direction is along the The total number of kinematic parameters to be identified
normal to the constraint plane. The probing steps are is reduced to 24.
normally set less than 1 mm hence the fine tuning steps
are less than 0.1 "(the repeatability of' the Renishaw
Table 1 Nominal Parameters of a Puma 560 Robot
probe is in the order of pm), thus achievcs a measurement
accuracy in the order of 0.1 mm which is sufficient for LinkNo. a;h"m ddmm) ahd) TOOL
robot calibration(if more accurate measuremcnt is required, 1 0 0 -~ 1 2 O.O(rad)
smaller probing steps can be set). In the special case when 2 431.8 149.09 0 O.O(rad)
the constraint planes are aligned with robot base planes, the 3 -28.32 0 7d2 O.O(rad)
robot only probe in one axis direction, the movements 4 0 433.07 -7~12 5(")
along the other two axis direclions are set to zero. 5 0 0 rc/2 O.O(mm)
6 - 0 56.25 0 302.34(mm)
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parameters "observable" from end-point positions, three level of robot repeatability after calibration. The cross-
constraint planes were placed perpendicular to each base evaluation has also been performed by collecting 20 test
axis. Forty random configurations in Cartesian space for points across robot workspace using precision external co-
each constraint plane were generated satisfying the ordinate measuring machine (CMM). The residual root
constraint conditions. Then the nominal inverse kinematic mean square errors for the test points are improved to 0.68
model was used to find the corresponding joint values for mm for position and 0.89 degree for orientation. The
each of Cartesian configurations. If there was no error in calibration results are consistent with the results of other
the kinematic model, it would be found that the positions calibration methods using sophisticated external
achieved by controlling those joint values would perfectly measurements.
match those constraint conditions. However, by inducing Table 2 Identified Errors of a Puma 560 Robot
small errors in the parameters(the induced errors were Link No. Aai(mm> Adi(") Acl,(rad) Aqi(rad)
randomly generated in the range of +2 mm for linear 1 0.761 0.031 0.0002 -0.0005
parameters and k0.02 radian for angular parameters), the 2 0.459 0.068 -0.0019 -0.0047
achieved positions by the 'actual' robot will deviate from 3 0.351 -0.091 0.0030 0.0024
the constraint planes(the dashed lines of Figure 3, the first 4 0.194 -0.445 0.0043 0.0176
40 points are the x component deviations of the 40 touch 5 0.026 -0.655 -0.0053 0.0036
points on the constraint plane perpendicular to x -axis from 6 0.075 -0.372 -0.0006 0.0017
the x-axis constraint plane; the next 40 points are the y
component deviations of the 40 points on the y-axis plane
from the y-axis plane and the last 40 are z component
deviations of the 40 points on the z-axis plane from the z-
axis plane). After calibrating the kinematic model using the
approach as presented in the previous sections, the
deviations from the constraint conditions are dramatically .......... I
reduced(the solid line in Figure 3). The identified errors are Before
almost identical to those induced. Calibration
To test the simulation results, the experimental set-up
was used for data collection(Figure 2). Three calibrated flat
planes were placed perpendicular to each of robot base axis After
for data collection. One hundred touch points on each of the Calibration
plane were collected. Sixty randomly chosen from each of
the 100 point were used for calibration and the remaining
points for independent test. Table 2 lists the identified
kinematic errors based on the calibration data. Figure 4 plot
-15 I I I I I I I
0 20 40 60 80 100 120
the x,y, and z component of the differences between each
two consecutive touch points on the same constraint Calibration Points
plane(the first 39 points are the difference of x components
obtained from the 40 test points on the constraint plane Figure 3. Simulation result with induced kinematic errors
perpendicular to the x-axis, and the next 39 are y
component differences obtained from the 40 test points on
the y-axis plane and the last 39 are z component differences 4
obtained from the 40 test points on the z-axis plane). The
dashed lines represent the differences of positions predicted
I I
by the un-calibrated model in the robot controller while the
solid lines represent the differences of positions predicted
by the updated model using the identified errors. The
symmetry of the graph is due to the use of the differences
between consecutive points. It is shown that the calibrated
model works well for test data points as well. Therefore it
reflects the true geometry of the robot rather than simply
the best fit of the calibration data. Using the reference
positions of the constraint planes perpendicular to the base Calibration
axis, we can evaluate directly the positioning accuracy
achieved by this calibration. Considering the positions
reported by the calibrated model as the reference positions I I I I I I
0 20 40 60 80 100 120
of the constraint planes, the accuracy comparisons based on
Test Points
the test points are given in Table 3. We can see that the
position accuracy of the robot has been improved to the
Figure 4. Test Result with experimental data
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Table 3 Accuracy Comparisons Based on Test Points [4] Whitney, D., Lozinsky and Rourke,J., 1986, "Industrial
Before Calibration After Calibration robot fonwartl calibration method and results", ASME J. of
(mm) dx 4 & d x dv d? Dynamic Systems, Measur. and Control, 108, PP. 1-8
avg. 1.210 4.545 1.313 0.198 0.175 0.210 151 Driels, lM.R., Swayze, LW and Potter L.S. 1993,
stdev. 0.196 0.737 0.213 0.032 0.028 0.034 "Full-pose calibration of a robot manipulator using a
max. 2.662 5.357 3.250 0.579 0.361 0.525 coordinate measuring machine", Int. J. of Adv Manuf
Technol 8: E'P. 34-41
6 Conclusions and Discussions [6] Zhong, X L , Lewis, J.M., and Rea, H., 1994, "Neuro-
accuracy Compensator for Industrial Robots", Proc. of
IEEE Int'l Con5 on Neural Networks, WCC1'94, Vol. 5 ,
A new autonomous robot calibration scheme has been PP. 2797-2802, Orlando, Florida
developed in this paper. Renishaw probes were originally [7] Prenninger, J.R., Vincze, M. and Gander, H, 1993,
used for workpiece setup and measurements for CNC "Contactless jpositjon and orientation measurement of robot
lathes. We applied these cost effective sensors successfully end-effector", IEEE Int. Con$ Robotics and Automation,
for robot on-site calibration in an industrial application Atlanta, Vol.1: PF'. 180-185
environment. Neither external measurements nor accurate [8] Mirnnan C.R. and Gupta K.C., 1992, "Compensation
fixture set-up are needed for such a calibration. The of Robot Joint Variables using Special Jacobian Matrices",
recurrent neural network-based parameter identification J. of Robotic System 9(1), PP. 113-137
algorithm is computationally more robust and efficient [9] Tang G.-R and Mooring B W, 1992, "Plane-Motion
than conventional least square methods. Both simulation Approach to Manipulator Calibration", Int J. of Adv
and experimental results for a Puma robot show that robot Manuf Technol, Vol. 7 PP 21-28
positioning accuracy can be improved to the level of robot [lo] Veitscheggei, W K and Wu, C-H, 1988, "Robot
repeatability. Calibration and Compensation", IEEE Int'l J of Robotics
To identify all kinematic parameters, normally more and Automation, Vol. 4 No 6, PP. 643-656
than one constraint plane is needed for data collection. [ l l ] Goswami, A, Quaid, A, and Peshkin, M, 1993,
Proper tool offsets are also needed to make the robot wrist "Complete parameter identification of a robot from partial
parameters identifiable. In the special case when constraint pose informa.tion", Proc. IEEE Int'l Con5 on Robotics
planes are aligned with robot base planes, three constraint and Automation, Vol. 1: PP. 168-173
planes peipendicular to each base co-ordinate axis are used [12] Driels, M.R. and Swayze,W., 1994, "Automated
for full parameter identifications. Our future work will partial pose measurement system for manipulator
investigate the optimal placement of the constraint planes calibration experiments", IEEE Trans. on Robotics and
in the constrained environments so that the robot has the Automation, Vol. 10, No. 4, PP. 430-440
optimal identification configurations. Constraint surfaces [13] Bennett :D. J., Geiger, D. and J.M. Hollerbach, 1991,
other than planes may also be suitable for the proposed "Autonomous Robot calibration for hand-eye co-
calibration method (such as a spherical ball) as long as the ordination", h t ' l J. of Robotics Research, VoL: 10, No.
surfaces have known shapes and are suitable for touching 5,PP:550-559
with the probe. [14] Zlhuang, H, Wang, L and Roth, Z.S, 1993,
Simultaneous calibration of a robot and a hand-mounted
Acknowledgements camera", Proc. IEEE Int'l Conf. on Robotics and
Automation, 'Vol. 2: PP. 149-154
The first author would like to acknowledge the CVCP [15] Newman, W.S. and Osbom, D.W., 1993, " A new
and Napier University for financial support for this method for kinematic parameter calibration via laser line
research. Our thanks are due to Mr Bill Campbell for his tracking", Proc. IEEE Int'l Con$ on Robotics and
contributions during the experiments and Prof. A R Young Automation, 'Vol. 2: PP. 160-165
for his encouragement. We are also grateful to the [16] D. Tank and J. Hopfield, 1986, "Simple 'Neural'
anonymous reviewers for useful comments. Optimisation Networks: An A/D Converter, Signal
Decision Circuit, and Linear Programming Circuit", IEEE
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