Synthesis of vision-based robot calibration using moving cameras

Robot calibration using a vision system and moving cameras is the focus of this dissertation. The dissertation contributes in the areas of robot modeling, kinematic identification and calibration measurement. The effects of perspective distortion of circular camera calibration points is analyzed. A new modified complete and parametrically continuous robot kinematic model, an evolution of the complete and parametrically continuous (CPC) model, is proposed. It is shown that the model's error-model can be developed easily as the structure of this new model is very simple and similar to the Denavit-Hartenbert model. The derivation procedure of the error-model follows a systematic method that can be applied to any kind of robot arms. Pose measurement is the most crucial step in robot calibration. The use of stereo as well as mono mobile camera measurement system for collection of pose data of the robot end-effector is investigated. The Simulated Annealing technique is applied to the problem of optimal measurement configuration selection. Joint travel limits can be included in the cost function. It is shown that trapping into local minimum points can be effectively avoided by properly choosing an initial point and a temperature schedule. The concept of simultaneous calibration of camera and robot is developed and implemented as an automated process that determines the system model parameters using only the system's internal sensors. This process uses a unified mathematical model for the entire robot/camera system. The results of the kinematic identification, optimal configuration selection, and simultaneous calibration of robot and camera using the PUMA 560 robot arm have demonstrated that the modified complete and parametrically continuous model is a viable and simple modeling tool, which can achieve desired accuracy. The systematic way of modeling and performing of different kinds of vision-based robot applications demonstrated in this dissertation will pave the way for industrial standardizing of robot calibration done by the robot user on the manufacturing floor.