Positioning accuracy improvement for target point tracking of robots based on Extended Kalman Filter with an optical tracking system

Although industrial robots have been successfully used in a wide spectrum of applications for production automation, they still face challenges for many high precision tasks especially in low-volume high-mix production due to their low absolute positioning accuracy. To respond to such rapidly changing production tasks, an efficient means is required to determine the pose relationship between the robot and the workpiece without human intervention such as teaching the robot. For this purpose, the paper proposes the use of the Extended Kalman Filter (EKF) with an optical tracking system to improve the robot positioning accuracy with a particular focus on the target point tracking of the end-of-arm tool, which is an essential part for many robotic tasks. To this end, a comprehensive kinematic error model is first derived for the end-of-arm tool that accounts for the errors in the Denavit-Hartenberg (D-H) parameters, the positioning errors of the robot base and the end-of-arm tool installation. Then, by using the optical tracking system, the pose of the end-of-arm tool relative to the workpiece can be determined in an efficient way. Based on the EKF algorithm, the kinematic parameter errors of the system can be estimated online to compensate the positioning error of the target point during the robot movement. Simulation and experimental tests have been performed to demonstrate the effectiveness of the proposed method. The proposed approach utilizes the given trajectory to design a compensation scheme where the kinematic parameter errors of the robot are estimated during the motion and then the positioning error of the end-of-arm tool is compensated at the target point. As a result, this approach can improve the target point accuracy of the robot without continuous feedback to reduce the tracking error along the trajectory in real time. It is easy to implement and suitable for low-volume, high-mix scenarios to determine the pose relationship between the robot and the workpiece without human intervention.