Design of a Two-Step Calibration Method of Kinematic Parameters for Serial Robots

Serial robots are used to handle workpieces with large dimensions, and calibrating kinematic parameters is one of the most efficient ways to upgrade their accuracy. Many models are set up to investigate how many kinematic parameters can be identified to meet the minimal principle, but the base frame and the kinematic parameter are indistinctly calibrated in a one-step way. A two-step method of calibrating kinematic parameters is proposed to improve the accuracy of the robot’s base frame and kinematic parameters. The forward kinematics described with respect to the measuring coordinate frame are established based on the product-of-exponential (POE) formula. In the first step the robot’s base coordinate frame is calibrated by the unit quaternion form. The errors of both the robot’s reference configuration and the base coordinate frame’s pose are equivalently transformed to the zero-position errors of the robot’s joints. The simplified model of the robot’s positioning error is established in second-power explicit expressions. Then the identification model is finished by the least square method, requiring measuring position coordinates only. The complete subtasks of calibrating the robot’s 39 kinematic parameters are finished in the second step. It’s proved by a group of calibration experiments that by the proposed two-step calibration method the average absolute accuracy of industrial robots is updated to 0.23 mm. This paper presents that the robot’s base frame should be calibrated before its kinematic parameters in order to upgrade its absolute positioning accuracy.