SYSTEM AND METHOD FOR CAMERA-BASED AUTO-ALIGNMENT
First Claim
1. A method for auto-alignment, comprising:
- gripping an X-Y calibration tool by a gripper unit of a robotic arm at a first height above a work surface on a first axis;
acquiring images of the X-Y calibration tool at the first height by a camera on a second axis, wherein the camera is coupled to the gripper unit; and
analyzing the images of the first calibration tool at the first height to determine an offset between the second axis and the first axis.
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Abstract
A camera-based auto-alignment process can include gripping a first calibration tool by a gripper unit of a robotic arm. Images of the first calibration tool can be captured by a camera coupled to the gripper unit. The gripper unit and camera unit can be aligned on two roughly parallel axes. The images can be analyzed to calibrate the axis of view of the camera with the gripper axis, providing an XY calibration of the robotic arm. The gripper unit can be calibrated on a Z-axis using optical calibration with landmarks provided on a second calibration tool, and/or by moving the gripper unit towards the work surface until it makes contact with the work surface and stops. Once calibrated, the camera can be used to identify one or more landmarks at known locations on the work surface to align the robotic arm with the work surface.
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Citations
23 Claims
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1. A method for auto-alignment, comprising:
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gripping an X-Y calibration tool by a gripper unit of a robotic arm at a first height above a work surface on a first axis; acquiring images of the X-Y calibration tool at the first height by a camera on a second axis, wherein the camera is coupled to the gripper unit; and analyzing the images of the first calibration tool at the first height to determine an offset between the second axis and the first axis. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for auto-alignment, comprising:
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positioning a gripper unit of a robotic arm at a predetermined height above a Z calibration tool, wherein the Z-calibration tool includes a plurality of landmarks on a plurality of levels; calibrating the gripper unit along a Z-axis over a first landmark on the Z calibration tool, wherein calibrating includes moving the gripper unit toward the first landmark on the Z calibration tool along the Z-axis until the gripper unit makes contact with the Z calibration tool; and determining a first number of steps traveled by the gripper unit from the predetermined height to making contact with the Z calibration tool. - View Dependent Claims (9, 10, 11)
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12. A method for auto-alignment, comprising:
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gripping a calibration tool by a gripper unit on a first axis; acquiring images of the calibration tool by a camera on a second axis, wherein the camera is connected to the gripper; analyzing the images to determine at least one distortion correction parameter, wherein the at least one distortion correction parameter can be used to correct lens-related distortions in the images; and applying the at least one distortion correction parameter to the images to produce distortion corrected images. - View Dependent Claims (13, 14, 15)
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16. An assembly, comprising:
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a robotic arm, including a gripper unit, wherein the robotic arm is configured to move in three dimensions over a work surface; and a camera coupled to the gripper unit such that the camera is maintained at a fixed height as the gripper unit moves along a Z axis substantially orthogonal to the work surface. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23)
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Specification