Automatic Calibration Method for the Relationship Between a Robotic Arm and a Two-Dimensional Profile Sensor

In this paper, an automated method is proposed for calibrating the relationship between the positions of a two-dimensional (2D) profile sensor and robotic arm. The proposed calibration method involves the use of a distance sensing module (containing three distance sensors), a 2D profile sensor, a ball with a known radius, and a motion controller installed on a robot flange. The motion controller converts the information recorded by the distance sensing module and 2D profile sensor into motion commands to facilitate the calibration of the relationship between the positions of a robotic arm and the 2D profile sensor. The proposed method is rapid and exhibits high precision and reliability. It does not require three-dimensional measurement devices and involves the use of a closed-form expression to determine solutions. This method is unaffected by errors that might lead to divergence during solution determination. Furthermore, the pro-posed method solves many problems associated with existing calibration methods for sensor coordinate systems, such as those related to the robotic arm’s dynamic error and the calibration block’s dimensional bias. The proposed method can be used in automated system integrators to shorten the system operation time and decrease automation costs.