Calibration of a flexible measurement system based on industrial articulated robot and structured light sensor

To realize online rapid measurement for complex workpieces, a flexible measurement system based on an articulated industrial robot with a structured light sensor mounted on the end-effector is developed. A method for calibrating the system parameters is proposed in which the hand-eye transformation parameters and the robot kinematic parameters are synthesized in the calibration process. An initial hand-eye calibration is first performed using a standard sphere as the calibration target. By applying the modified complete and parametrically continuous method, we establish a synthesized kinematic model that combines the initial hand-eye transformation and distal link parameters as a whole with the sensor coordinate system as the tool frame. According to the synthesized kinematic model, an error model is constructed based on spheres’ center-to-center distance errors. Consequently, the error model parameters can be identified in a calibration experiment using a three-standard-sphere target. Furthermore, the redundancy of error model parameters is eliminated to ensure the accuracy and robustness of the parameter identification. Calibration and measurement experiments are carried out based on an ER3A-C60 robot. The experimental results show that the proposed calibration method enjoys high measurement accuracy, and this efficient and flexible system is suitable for online measurement in industrial scenes.