Integrating laser profile sensor to an industrial robotic arm for improving quality inspection in manufacturing processes

Abstract

This paper investigates the integration of laser profile sensor to an industrial robotic arm for automating the quality inspection in manufacturing processes that requires a manual labour intensive work. The aim was to register the measurements from a laser profile sensor mounted on a six degrees-of-freedom robot with respect to the robot base frame. The registration is based on a six degrees-of-freedom calibration, which is an essential step for several automated manufacturing processes that require high level of accuracy in tool positioning and alignment on one hand, and quality inspection systems that require flexibility and accurate measurements on the other hand. The investigation compromises of two calibration procedures namely the calibration using a sharp object and the planar constraints. The solution of the calibration procedures estimated from both iterative and optimization solvers is thoroughly discussed. By implementing a simulation platform that generates virtual data for the two procedures with additional levels of noise, the six-dimensional poses are estimated and compared to the ground truth. Finally, an experimental test using a laser profile from Acuity mounted on Mitsubishi RV-6SDL manipulator is presented to investigate the measurement accuracy with four estimated laser poses. The calibration procedure using a sharp object shows the most accurate simulation and experimental results under the effect of noise.