CN108692688B - Automatic calibration method for coordinate system of scanner of robot measuring-processing system - Google Patents
Automatic calibration method for coordinate system of scanner of robot measuring-processing system Download PDFInfo
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Abstract
The invention discloses an automatic calibration method for a coordinate system of a scanner of a robot measuring-processing system, which comprises the steps of firstly establishing a cooperative calibration working flow of robot motion and scanner scanning, secondly establishing a scanning point data processing method of the scanner, and finally establishing a conversion matrix of the coordinate system of the scanner and the coordinate system of the robot according to a coordinate transformation relation, thereby completing the automatic calibration of the coordinate system of the scanner. The invention overcomes the defects of complicated procedures of calibration by the traditional manual operation robot, tool clamping errors in the calibration process and the like, is easy to realize the automatic calibration of the coordinate system of the scanner of the robot measuring-processing system, can be widely applied to the measuring-processing system of the complex part robot in the fields of aviation, aerospace, automobiles, high-speed rail, energy and the like, and obviously improves the processing precision.
Description
Technical Field
The invention belongs to the technical field of industrial robots, and particularly relates to an automatic calibration method for a coordinate system of a scanner of a robot measuring-processing system.
Background
With the rapid development of industrial robot technology, the measurement processing system based on the robot is widely applied to processing of various parts in the fields of aviation, aerospace, automobiles, high-speed rails, energy sources and the like, gradually replaces the traditional manual operation mode, and realizes the production automation of the parts. In order to ensure good machining accuracy, the measurement system (scanner) needs to be calibrated and the positional relationship between the robot coordinate system and the measurement system needs to be determined by a coincident point. The method for calibrating by adopting the manual operation robot has the disadvantages of complicated process, high operation difficulty and high technical requirement level for operators. The chinese patent application No. 201510483410.0 discloses a robot hand-eye calibration method based on a scanner, which provides a calibration method for scanning a robot end clamping tool by using the scanner to obtain the actual position of the scanner coordinate system relative to the robot end coordinate system.
Disclosure of Invention
The invention provides an automatic calibration method for a coordinate system of a scanner of a robot measuring-processing system, which adopts a repositioning mode, has the characteristics of higher precision and easy realization of automatic calibration in the whole process, and can be widely applied to surface scanning and line scanning robot measuring-processing systems.
The technical scheme adopted by the invention for solving the technical problems is as follows:
an automatic calibration method for a coordinate system of a scanner of a robot measuring-processing system comprises the following steps:
s1, establishing a robot motion and scanner scanning cooperative calibration workflow: selecting at least four different-surface tools 0 in a robot coordinate system, clamping a standard ball at the tail end of the robot, controlling the robot to execute a motion program and a scanner to execute a scanning program by an upper computer, scanning the standard ball at any tool0 position by the scanner in at least four different postures, and returning point track information obtained by the motion of the robot and the scanning of the scanner to the upper computer;
s2, establishing scanner scanning point data: according to a point data processing method, the upper computer extracts point clouds of the standard spherical surfaces, the center coordinates of all the standard spheres in a scanner coordinate system are obtained through calculation, and then the fitting center coordinates are obtained through calculation;
s3, establishing a conversion matrix of the scanner coordinate system and the robot coordinate system through a coordinate transformation relation, and calculating to obtain the conversion matrix according to the tool0 position in the robot coordinate system in the step S1 and the fitting sphere center coordinate in the step S2, thereby realizing the automatic calibration of the scanner coordinate system.
According to the technical scheme, in the step S1, the positions of four different-surface tools 0 are respectively marked as a point a, a point b, a point c and a point d, the robot clamps a standard ball to make linear motion along the y axis a to b, the z axis b to c and the x axis c to d of a robot coordinate system in the field of view of the scanner, the robot returns to the tool0 position under the robot coordinate system when reaching the end point of one linear motion, and repositioning motion is performed at the end point of each linear motion by taking the tool0 as a TCP point.
According to the technical scheme, in the step S1, the distances between the point a and the point b, the point b and the point c, and the point c and the point d are all 100 mm.
According to the technical scheme, in the step S1, four different postures are respectively recorded as a posture a, a posture B, a posture C and a posture D, the posture a is given by the user, and the posture B, the posture C and the posture D are generated by fixing the rotation angle and are uniformly distributed around the posture a.
According to the above technical solution, step S2 includes:
s201, standard spherical point cloud extraction: extracting the standard point cloud of a scanning point cloud containing an environment such as a fixture by adopting a section method, specifically adopting x ═ xminAnd x ═ xmin+ d two truncation planes intercept the point cloud, where xminIs the minimum value of the abscissa of the point cloud, 0<d<Rb，RbIs the standard sphere radius;
s202, standard sphere center calculation: extracting standard spherical point cloud from the scanning point cloud, and calculating standard spherical center coordinate (x) by adopting least square method to perform spherical fitting according to the position information of the spherical point cloud0,y0,z0) The expression is as follows:
ei(x0,y0,z0,R)＝(xi-x0)2+(yi-y0)2+(zi-z0)2-R2(1)
wherein (x)i,yi,zi) Is the point cloud coordinate of the standard spherical surface, R is the radius of the fitting standard spherical surface, and the formula (2) satisfies
Solving equation (3) to obtain the standard sphere center coordinate (x)0,y0,z0)；
S203, calculating a fitting sphere center: and respectively obtaining A, B, C, D standard spherical centers Q1(x, y and z) under four different postures by setting the coordinates of the fitted spherical centers as (x, y and z) and the radius as r01,y01,z01)，Q2(x02,y02,z02)，Q3(x03,y03,z03) And Q4 (x)04,y04,z04) And satisfies the following formula:
solving (x, y, z) by formula (4), namely obtaining the coordinates of the fitted sphere center and the tool0 coordinate value (x) under the scanner coordinate systems,ys,zs) The coordinates of the four fitting spherical centers of a, b, c and d are obtained by calculation
According to the above technical solution, step S3 includes:
s301, according to the sphere center coordinate of tool0 point fitting under the scanner coordinate system
The position information of the four different plane tools 0 at the scanning point returned by the robot is recorded as
S302, setting a rotation matrix of converting a scanner coordinate system into a robot coordinate system as TrThe translation matrix is TmTherefore, four points a, b, c, and d satisfy the following equation:
solving equation (5) yields a rotation matrix of
Let the translation matrix Tm＝(xmymzm) For any point (x) in the scanner coordinate systems,ys,zs) Converted into the robot coordinate system (x)r,yr,zr) The following are true:
substituting coordinates of any point among a, b, c and d to obtain translation matrix Tm。
The invention has the following beneficial effects: according to the invention, by establishing the conversion relation between the robot coordinate system and the scanner coordinate system, the complex process of calibration of the traditional manual operation robot and the clamping error in the calibration process are overcome, the calibration precision can be obviously improved, and the automation of the calibration process is realized.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic view of a metrology process system in an embodiment of the present invention;
FIG. 2 is a schematic diagram of an automatic calibration method according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a calibration process of the robot and the scanner in cooperation in the embodiment of the present invention;
FIG. 4 is a simplified diagram of a standard spherical point cloud extraction according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a four-point method for calculating a fitted sphere center according to an embodiment of the present invention;
FIG. 6 is a schematic diagram of coordinate transformation in an embodiment of the present invention;
FIG. 7 is a flowchart of the automated calibration software in an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
An automatic calibration method for a coordinate system of a scanner of a robot measuring-processing system comprises the following steps:
s1, establishing a robot motion and scanner scanning cooperative calibration workflow: as shown in fig. 1, at least four different-surface tools 0 are selected from a robot coordinate system, a standard ball 2 is clamped at the tail end of a robot 1, an upper computer 4 controls the robot 1 to execute a motion program and a scanner 3 to execute a scanning program, so that the standard ball 2 at any tool0 position is scanned by the scanner in at least four different postures, point track information obtained by robot motion and scanner scanning is returned to the upper computer, and tool0(TCP) position information at a scanning point is returned at the same time;
s2, establishing scanner scanning point data: as shown in fig. 4, according to the point data processing method, the upper computer extracts the point cloud of the standard spherical surface, calculates to obtain the center coordinates of all the standard spheres in the scanner coordinate system, and then calculates to obtain the fitting center coordinates;
s3, as shown in FIG. 6, a transformation matrix of the scanner coordinate system and the robot coordinate system is established through a coordinate transformation relation, and the transformation matrix is obtained through calculation according to the tool0 position in the robot coordinate system in the step S1 and the fitted sphere center coordinate in the step S2, so that the automatic calibration of the scanner coordinate system is realized.
In a preferred embodiment of the present invention, as shown in fig. 3, in step S1, the positions of the four out-of-plane tools 0 are respectively marked as a point a, a point b, a point c, and a point d, the robot clamps the standard ball to make linear motion along the y-axis (negative direction) a to b, the z-axis b to c, and the x-axis c to d of the robot coordinate system within the field of view of the scanner by using tool0 as TCP (tool center point), specifically, the distances between the point a and the point b, the point b and the point c, and the point c and the point d are all 100mm, the standard ball is scanned by the scanner in four postures of A, B, C, D at the four points a, b, c, and d, wherein the posture a is given by the user, the posture B, C, D is generated by a fixed rotation angle and is uniformly distributed around the posture a, the centers of the standard balls under the four postures of A, B, C, D are not coplanar, the robot returns to the tool0 position under the robot coordinate system every time when the robot, and the robot performs repositioning movement with the tool0 as a TCP point at the end point of each linear movement (namely, when the robot moves to a, the robot performs repositioning movement with the tool0 as a TCP). In the process, the motion of the robot and the scanning instruction of the scanner are triggered by the upper computer, so that the purpose of cooperative calibration is achieved.
In a preferred embodiment of the present invention, step S2 includes:
s201, standard spherical point cloud extraction: as shown in fig. 4, a scanning point cloud containing an environment such as a jig is extracted by a cross-section method, specifically, x is xminAnd x ═ xmin+ d two truncation planes intercept the point cloud, where xminIs the minimum value of the abscissa of the point cloud, 0<d<Rb，RbIs the standard sphere radius;
s202, standard sphere center calculation: extracting standard spherical point cloud from the scanning point cloud, and calculating standard spherical center coordinate (x) by adopting least square method to perform spherical fitting according to the position information of the spherical point cloud0,y0,z0) The expression is as follows:
ei(x0,y0,z0,R)＝(xi-x0)2+(yi-y0)2+(zi-z0)2-R2(1)
wherein (x)i,yi,zi) Is the point cloud coordinate of the standard spherical surface, R is the radius of the fitting standard spherical surface, and the formula (2) satisfies
Solving equation (3) to obtain the standard sphere center coordinate (x)0,y0,z0)；
S203, calculating a fitting sphere center: as shown in FIG. 5, assuming the coordinates of the fitted sphere center as (x, y, z) and the radius as r, the standard sphere center Q1 (x) of A, B, C, D in four different postures is obtained respectively01,y01,z01)，Q2(x02,y02,z02)，Q3(x03,y03,z03) And Q4 (x)04,y04,z04) And satisfies the following formula:
solving (x, y, z) by formula (4), namely obtaining the coordinates of the fitted sphere center and the tool0 coordinate value (x) under the scanner coordinate systems,ys,zs) The coordinates of the four fitting spherical centers of a, b, c and d are obtained by calculation
In a preferred embodiment of the present invention, after the calculation of the fitted sphere center is completed, a rotation matrix between a robot coordinate system and a scanner coordinate system is calculated according to the robot motion path, a coordinate transformation schematic diagram is shown in fig. 6, and step S3 includes:
s301, according to the sphere center coordinate of tool0 point fitting under the scanner coordinate system
The position information of the four different plane tools 0 at the scanning point returned by the robot is recorded as
b
S302, setting a rotation matrix of converting a scanner coordinate system into a robot coordinate system as TrThe translation matrix is TmTherefore, four points a, b, c, and d satisfy the following equation:
solving equation (5) yields a rotation matrix of
Let the translation matrix Tm＝(xmymzm) For any point in the scanner coordinate system
Conversion into the robot coordinate system (x)r,yr,zr) The following are true:
substituting coordinates of any point among a, b, c and d to obtain translation matrix Tm。
Taking the a-point A attitude calculation as an example:
1. extracting standard spherical point cloud: using x as xminAnd x ═ xmin+0.75RbTwo cross-sectional planes intercept the point cloud, as shown in FIG. 4, where xminIs the minimum value of the horizontal coordinate of the point cloud,is the standard sphere radius;
2. calculating the standard sphere center: solving the formula (3) to obtain the standard sphere center coordinate (x)0,y0,z0) The radius R of the fitted standard sphere is calculated by formula (8) and is judgedbWhether the R < I > is less than or equal to 0.01mm is satisfied or not so as to judge the accuracy and the validity of the standard spherical center coordinate, if not, the rotating robot repeats scanning calculation on the sixth axis, the spherical center coordinate corresponding to the closest R value is selected as the standard spherical center coordinate,
3. calculating the fitting spherical center: similarly, the standard sphere center is calculated for the posture of the point a B, C, D according to the step 1.2, and the coordinate of the point is obtained by solving (x, y, z) through the formula (4), and is also the coordinate value of the tool0 in the scanner coordinate system, and is recorded as the coordinate value of the tool0
b. c and d, the calculation process is the same as that of a.
The main principle of the present invention, as shown in fig. 2, includes the following steps:
s1, establishing a robot movement and scanner scanning cooperative calibration workflow;
s2, establishing a scanner scanning point data processing method;
and S3, acquiring data through the step S2, and establishing a conversion matrix of the scanner coordinate system and the robot coordinate system according to the coordinate conversion relation, so that the automatic calibration of the scanner coordinate system is realized.
Fig. 7 shows an automated calibration process implemented in the measurement processing system according to the present invention.
It will be understood that modifications and variations can be made by persons skilled in the art in light of the above teachings and all such modifications and variations are intended to be included within the scope of the invention as defined in the appended claims.
Claims (6)
1. An automatic calibration method for a coordinate system of a scanner of a robot measuring-processing system is characterized by comprising the following steps:
s1, establishing a robot motion and scanner scanning cooperative calibration workflow: selecting at least four different-surface tools 0 in a robot coordinate system, clamping a standard ball at the tail end of the robot, controlling the robot to execute a motion program and a scanner to execute a scanning program by an upper computer, scanning the standard ball at any tool0 position by the scanner in at least four different postures, and returning point track information obtained by the motion of the robot and the scanning of the scanner to the upper computer;
s2, establishing scanner scanning point data: according to a point data processing method, the upper computer extracts point clouds of the standard spherical surfaces, the center coordinates of all the standard spheres in a scanner coordinate system are obtained through calculation, and then the fitting center coordinates are obtained through calculation;
s3, establishing a conversion matrix of the scanner coordinate system and the robot coordinate system through a coordinate transformation relation, and calculating to obtain the conversion matrix according to the tool0 position in the robot coordinate system in the step S1 and the fitting sphere center coordinate in the step S2, thereby realizing the automatic calibration of the scanner coordinate system.
2. The method as claimed in claim 1, wherein in step S1, the positions of the four out-of-plane tools 0 are respectively marked as a point a, a point b, a point c, and a point d, the robot holds the calibration sphere to perform linear motions along the y-axis a to b, the z-axis b to c, and the x-axis c to d of the robot coordinate system in turn within the field of view of the scanner, the robot returns to the tool0 position in the robot coordinate system every time the end point of one linear motion is reached, and performs repositioning motion with the tool0 as the TCP point at each end point of the linear motion.
3. The automatic calibration method for the coordinate system of the scanner of the robotic measuring-processing system as defined in claim 2, wherein the distances between the point a and the point b, between the point b and the point c, and between the point c and the point d in step S1 are all 100 mm.
4. The method for automatically calibrating the coordinate system of a scanner of a robotic measurement-machining system of claim 2, wherein in step S1, four different poses are respectively recorded as pose a, pose B, pose C, and pose D, wherein pose a is given by a user, and pose B, pose C, and pose D are generated by a fixed rotation angle and are uniformly distributed around pose a.
5. The automatic calibration method for the coordinate system of the scanner of the robotic measuring-machining system according to claim 4, wherein the step S2 comprises:
s201, standard spherical point cloud extraction: for scanning point cloud containing fixture environment, cross section method is adopted for benchmarkingExtracting quasi-spherical point cloud, specifically adopting x ═ xminAnd x ═ xmin+ d two truncation planes intercept the point cloud, where xminIs the minimum value of the abscissa of the point cloud, 0<d<Rb，RbIs the standard sphere radius;
s202, standard sphere center calculation: extracting standard spherical point cloud from the scanning point cloud, and calculating standard spherical center coordinate (x) by adopting least square method to perform spherical fitting according to the position information of the spherical point cloud0,y0,z0) The expression is as follows:
ei(x0,y0,z0,R)＝(xi-x0)2+(yi-y0)2+(zi-z0)2-R2(1)
wherein (x)i,yi,zi) Is the point cloud coordinate of the standard spherical surface, R is the radius of the fitting standard spherical surface, and the formula (2) satisfies
Solving equation (3) to obtain the standard sphere center coordinate (x)0,y0,z0)；
S203, calculating a fitting sphere center: and respectively obtaining A, B, C, D standard spherical centers Q1(x, y and z) under four different postures by setting the coordinates of the fitted spherical centers as (x, y and z) and the radius as r01,y01,z01)，Q2(x02,y02,z02)，Q3(x03,y03,z03) And Q4 (x)04,y04,z04) And satisfies the following formula:
solving (x, y, z) by formula (4), i.e. obtaining a seat fitting the centre of sphereThe target, and at the same time, the coordinate value (x) of tool0 in the scanner coordinate systems,ys,zs) The coordinates of the four fitting spherical centers of a, b, c and d are obtained by calculation
6. The automatic calibration method for the coordinate system of the scanner of the robotic measuring-machining system according to claim 5, wherein the step S3 comprises:
s301, according to the sphere center coordinate of tool0 point fitting under the scanner coordinate system
S302, setting a rotation matrix of converting a scanner coordinate system into a robot coordinate system as TrThe translation matrix is TmTherefore, four points a, b, c, and d satisfy the following equation:
solving equation (5) yields a rotation matrix of
Let the translation matrix Tm＝(xmymzm) For any point (x) in the scanner coordinate systems,ys,zs) Converted into the robot coordinate system (x)r,yr,zr) The following are true:
substituting coordinates of any point among a, b, c and d to obtain translation matrix Tm。
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