A closed-loop calibration method for serial robots based on position constraints and local area measurement

This paper presents a cost-effective and efficient closed-loop calibration method to enhance the absolute positioning accuracy of industrial robots. The method utilizes an economical and highly accurate set of simple measurement devices, including a device mounted on the robot's end effector and a spherical constraint device positioned within the robot's workspace. A novel local area measurement method is employed for the spherical constraint device, effectively converting position errors into the errors in the sphere center position of the constraint device. Furthermore, the error model considers both kinematic parameter deviations of the robot itself as well as those of the measurement device, along with non-kinematic errors caused by link self-weight. The closed-loop calibration model relies on position constraints, enabling identification and compensation of all error parameters using Levenberg Marquardt method after substituting measured data. The effectiveness of this proposed method is demonstrated through simulation and experimentation. In simulations, average position error reduces from 8.249 mm to 0.8384 mm, while absolute mean difference in sphere center positions obtained using our measurement equipment decreases from 1.206 mm to 0.1027 mm. Significant reductions in both position error and difference in sphere center position are indicated after calibration. This proves that the absolute mean value of the sphere center position difference can be used as the basis for judging the size of the robot's end position error. Experimental results show that absolute mean difference in sphere center position decreases from 0.4319 mm to 0.02869 mm, leading to substantial improvement in overall positioning accuracy.