Enhanced 6D Measurement by Integrating an Inertial Measurement Unit (IMU) with a 6D Sensor Unit of a Laser Tracker

Six-degree-of-freedom (6D) sensors enhance the measurement capability of traditional three-degree-of-freedom (3D) laser trackers. However, the classical 6D measurement techniques still have shortcomings in actual use, such as the problem of line of sight and relatively low data acquisition rate. The proposed approach by integrating an Inertial Measurement Unit (IMU) with a 6D sensor unit of a laser tracker is effective to overcome these limitations. The error is corrected by the combination of a Kalman filter and a backward smoothing algorithm. The Kalman filter only works when the 6D sensor's data is being sent through, while the backward smoothing algorithm works during the whole process. The experiments are performed to compare the error in three positions and three rotational orientations between the proposed method and the Kalman filter and evaluate the effects of different rates and IMU frequencies on the algorithm. The simulations are also performed to estimate the maximum outage time. The results verify that the proposed method can solve the problem of line of sight and low data acquisition rate effectively.</p

Design and development of a ceiling-mounted workshop measurement positioning system for large-scale metrology

This paper presents a new ceiling-mounted workshop Measurement Positioning System (C-wMPS) compensating for many deficiencies shown by conventional metrology systems, especially on the possibility of task-oriented designing for coverage ability, measurement accuracy and efficiency. A hybrid calibration system consisting of a high-precision coordinate control field and standard lengths is developed and implemented for the C-wMPS, which can be designed concretely to provide both traceability and the ability of local accuracy enhancement. Layout optimization using a genetic algorithm based on grids is applied to design an appropriate layout of the system, therefore promotes the system’s performance and reduce cost. An experiment carried out at the Guidance, Navigation and Control laboratory (GNC lab, 40×30×12m) validates the prominent characteristic of C-wMPS and the fitness of the new calibration system and layout optimization method.<br/

Integrated calibration of a 3D attitude sensor in large-scale metrology

A novel calibration method is presented for a sensor fusion system in large-scale metrology, which improves the calibration efficiency and reliability. The attitude sensor is composed of a pinhole prism, a converging lens, an area-array camera and a biaxial inclinometer. A mathematical model is established to determine its three-dimensional attitude relative to a cooperative total station by using two vector observations from the imaging system and the inclinometer. The measurement model developed has two aspects to be calibrated: the intrinsic parameters of the imaging model; and the transformation matrix between the camera and the inclinometer. An integrated calibration method using a three-axis rotary table and a total station is then proposed. A single mounting position of the attitude sensor on the rotary table is sufficient to solve for all parameters of the measurement model. A correction technique for the reference laser beam of the total station removes the need for accurate positioning of the sensor on the rotary table. Calibration measurements are made at multiple angular positions of the rotary table in order to determine all the unknown parameters in the model. Experimental verification has verified the practicality and accuracy of this calibration method. Results show that the mean deviations of attitude angles using the proposed method are less than 0.01°

Design of an omnidirectional single-point photodetector for large-scale spatial coordinate measurement

In high precision and large-scale coordinate measurement, one commonly used approach to determine the coordinate of a target point is to utilize the spatial trigonometric relationships between multiple laser transmitting stations and the target point. A light receiving device at target point is the key element in large-scale coordinate measurement systems. To ensure high-resolution and highly-sensitive spatial coordinate measurement, a high-performance and miniaturized omnidirectional single-point photodetector (OSPD) is highly desired. Here we report one design of OSPD using aspheric lens, which achieves enhanced reception angle of -5 to 45 degree in vertical and 360 degree in horizontal. As the heart of our OSPD, the aspheric lens is designed in geometric model and optimized by LightTools Software, which enables reflecting wide-angle incident light beam into the single-point photodiode. The performance of home-made OSPD is characterized with working distances from 1 m to 13 m and further analyzed utilizing established geometric model. The experimental and analytic results verify that our new device is highly suitable for large-scale coordinate metrology. The developed device also holds great potential in various applications such as omnidirectional vision sensor, indoor global positioning system, optical wireless communication systems

Rapid Global Calibration Technology for Hybrid Visual Inspection System

Vision-based methods for product quality inspection are playing an increasingly important role in modern industries for their good performance and high efficiency. A hybrid visual inspection system, which consists of an industrial robot with a flexible sensor and several stationary sensors, has been widely applied in mass production, especially in automobile manufacturing. In this paper, a rapid global calibration method for the hybrid visual inspection system is proposed. Global calibration of a flexible sensor is performed first based on the robot kinematic. Then, with the aid of the calibrated flexible sensor, stationary sensors are calibrated globally one by one based on homography. Only a standard sphere and an auxiliary target with a 2D planar pattern are applied during the system global calibration, and the calibration process can be easily re-performed during the system’s periodical maintenance. An error compensation method is proposed for the hybrid inspection system, and the final accuracy of the hybrid system is evaluated with the deviation and correlation coefficient between the measured results of the hybrid system and Coordinate Measuring Machine (CMM). An accuracy verification experiment shows that deviation of over 95% of featured points are less than ±0.3 mm, and the correlation coefficients of over 85% of points are larger than 0.7

Monocular-Based 6-Degree of Freedom Pose Estimation Technology for Robotic Intelligent Grasping Systems

Industrial robots are expected to undertake ever more advanced tasks in the modern manufacturing industry, such as intelligent grasping, in which robots should be capable of recognizing the position and orientation of a part before grasping it. In this paper, a monocular-based 6-degree of freedom (DOF) pose estimation technology to enable robots to grasp large-size parts at informal poses is proposed. A camera was mounted on the robot end-flange and oriented to measure several featured points on the part before the robot moved to grasp it. In order to estimate the part pose, a nonlinear optimization model based on the camera object space collinearity error in different poses is established, and the initial iteration value is estimated with the differential transformation. Measuring poses of the camera are optimized based on uncertainty analysis. Also, the principle of the robotic intelligent grasping system was developed, with which the robot could adjust its pose to grasp the part. In experimental tests, the part poses estimated with the method described in this paper were compared with those produced by a laser tracker, and results show the RMS angle and position error are about 0.0228° and 0.4603 mm. Robotic intelligent grasping tests were also successfully performed in the experiments