Proceedings of the 35th ISR (International Symposium on Robotics) 23-26 March, 2004

Metrology-integrated Industrial Robots –

Calibration, Implementation and Testing

Henrik Kihlman, Raimund Loser, Andrew Cooke,

henrik.kihlman@ikp.liu.se raimund.loser@leica-geosystems.com andrew.r.cooke@baesystems.com
Albin Sunnanbo, Konrad von Arb,
Albin.sunnanbo@ikp.liu.se konrad.von-arb@leica-geosystems.com
Linköping University Leica Geosystems AG BAE SYSTEMS
Dept. of Mechanical Engineering Metrology Division Advanced Technology Centre
SWEDEN SWITZERLAND UNITED KINGDOM
ABSTRACT model. Attempts to use robots for more demanding
This paper presents integration of a metrology system operations, such as drilling has been undertaken in
and an industrial robot. The metrology system this research with success. Another demanding
consists of a laser tracker that measures the distance operation studied in this research and presented in
to a prism with high accuracy and a camera that this paper is to use the robot to perform
through photogrammetry measures the orientation of reconfiguration in a flexible fixture. In order to reach
a reflector. Both laser prism and camera reflector is and maintain high accuracy, this paper is presenting
integrated to a 6D-Reflector that is attached close to an approach to have a metrology system online with
the TCP of an industrial robot. Tracker and robot is the robot controller to compensate for errors
connected to a PC on a TCP/IP network. The PC continuously. This removed much of the calibration
takes measurements with the tracker, and thereby work, since most of the calibrations were performed
compensates the robot to reach high absolute online. The metrology system uses a laser tracker to
accuracy in the robot positioning (+/-50 µm). The measure the position of the robot Tool-Center-Point
6D-Reflector has multi-functionality and simplifies (TCP) and an additional camera to measure
calibration procedures. This paper explains the orientation. Tests have been undertaken where the
architecture of the system and the methods for robot reaches 0.05 mm positional accuracy and 0.04
calibration. degrees in angular accuracy. This paper includes an
introduction to the hardware used in the installation,
Keywords: metrology, laser, photogrammetry, robot, calibration methods and results from the integration
online control, calibration tests. This paper is a continued session from an earlier
published by Kihlman & Loser, 2003 (6). In the
1 INTRODUCTION previous paper, due to technical problems and delays,
all the final results could not be published in time.
Industrial Robots have been developed from the This paper covers these results plus more.
beginning essentially for automating welding in the
Automotive Industry and has been used for many
years with success. In the Aerospace Industry 2 ROBOT ACCURACY
automation is much more expensive for several Industrial robots have for many years been used in
reasons. Two major reasons are the low product great extent in Automotive Industry. Aerospace
volumes, and high demands on accuracy. Automation Industry is now prudent to reduce cost and shorten
in Aerospace Industry has mainly been accomplished lead-times, where large dedicated machines have
through highly dedicated machines. The level of been the common method for automation. These
interest in using Industrial Robots for automation in machines have been a guarantee for enabling high
Aerospace Manufacturing has increased in recent accuracy in difficult operations, such as drilling and
years. On the market today, there exists several assembly of high quality products. These machines
examples of High-Accuracy Robots. High-Accuracy however, are expensive and lack flexibility.
Robots are subject to a calibration phase prior to Therefore, Aerospace Industry has now realised the
delivery. This provides an absolute accuracy in the potential of using industrial robots for automation.
order of 0.5 mm or in some cases even higher. This Automotive Industry has also put out new demands
method requires the robot process load to be in on the robots to handle new tasks, which requires
direction of gravity and static, so that the robot higher precision. Amongst others, these two scenarios
controller can maintain the accuracy. On the market have led to robot suppliers increasing the capability
there exist methods for cell-calibration, where robot on their robots; hence today robot providers are
and end-effectors are calibrated to perform certain presenting new robots with high accuracy programs.
tasks that requires higher accuracy. These methods
however, require the process forces to remain the 2.1 Resolution in robots
same over time. In some processes the conditions are
difficult to predict, such as processes with dynamic What makes robots reach high accuracy using a
loads i.e. drilling, or friction when manipulating metrology system is neither repetitive- nor absolute
flexible fixtures. These scenarios could be solved if accuracy itself. What is important is the resolution of
there existed perfect models of the system. These the robot. Resolution on the other hand often goes
systems however are complex and are difficult to hand in hand with high repetitive accuracy. Let us
 Proceedings of the 35th ISR (International Symposium on Robotics) 23-26 March, 2004

look at the robot used for the experiments - an singularities using the pointing mode. When joint 4
IRB4400 from ABB. The repetitive accuracy in that and joint 6 is passing through zero axis degrees, these
robot is 50µm. To reach that accuracy in the full work kinds of robots will cause strange behaviours.
volume, the resolution of the robot is much higher. Pointing mode is also difficult for the robot to
Tests performed in this research have proven the manage if the weight of the end-effector is to high,
robot to able to move in a resolution of 5um. When which will cause a torque on joint 5. For example, the
fine adjustments have been carried out, the robot IRB4400/60 used in the experiments manages 60 kg
controller is simply given a new absolute position in at maximum 27 cm (16.2 Nm) out from the TCP.
the base coordinate system. Helin, 2002 (3) presented
tests results from ABB’s High-accuracy program. 2.3 Friction in workobject
The results clearly showed that it is easier to reach Also in this research the robot has been tested as a
higher accuracy in smaller robots. One trend in manipulator for flexible tooling (4),(5). The robot is
Aerospace Industry nowadays is to buy large robots docking with tooling modules and configures them,
for being able to carry multi-end-effectors weighting see figure 2. The tooling modules presented in that
several 100kg. It is contradictory to use large robots research can be manipulated in 6DOF. Using the
when high accuracy is required. This indicates that robot to change the configuration of a mechanism
end-effector suppliers should consider building however is a challenging task, especially in fine
smaller end-effectors if they are to be fine adjusted, adjustment. There was a clear indication that it is
which requires smaller robots and the question arising more difficult to position a robot in high accuracy if it
to the end-effector suppliers today is: How will large is exerted for friction. Tests performed in this
end-effectors be positioned with high accuracy? To research verify this hypothesis. In general, the time to
give better understanding to the background to this reach high accuracy becomes longer if the robot is
research, the next two section will presented why moving a fixture module. Some tests have also
extensive calibration procedures will not help to resulted in overshooting when compensating the
maintain high precision in some scenarios. datum point of the fixture module.
2.2 Dynamic loads
Drilling using an Industrial Robot is an example
where
Joint forces
5 change rapidly. Today, suppliers for
drilling end-effectors handle this problem either by
pre-pressurising the drill bushing, or a pressure foot
on the drilling end-effector. This introduces forces to
the robot. To eliminate disturbances on the robot the
pre-pressure force must be significantly higher than
the axial drilling force, to ensure that the drilling end-
effector will maintain its position and orientation
during drilling. One problem here, is that, the
direction of the drilling force, is seldom in the same
direction as a hanging load. Robots today are not able
to compensate for forces other than gravitational. Figure 2: Robot-manipulated Tooling
This will cause problems like slip-stick etc. (1). Also,
when using large and heavy end-effectors it is
common to have the end-effector installed in a The conclusion from this section is that even highly
hanging mode on the robot to avoid unnecessary calibrated robots would not help in applications
torque in joint 5 such as figure 1a. When applying where the process force changes rapidly or if friction,
pre-pressure force on the end-effector joint 5 will be which is not static, is involved. One solution to cope
exerted to high forces, in some cases more force than with these problems is to have a metrology system
the weight of the end-effector itself. online with the robot. That is what the rest of this
paper will present.

3 EXPERIMENTAL SETUP
Most of the hardware for the metrology integration
has been presented by Kihlman & Loser, 2003 (6),
but to keep this paper together, the components will
briefly be presented in this section.

Figure 1a Figure 1b 3.1 The LTD800

Normally Laser Trackers are based on measurements
Weakness in joint 5 was presented by Kihlman et. al, of a single reflector. Whereas laser interferometers in
2002 (7). To avoid deflection and slip-stick, the general must track the reflector relatively from a fine
correct configuration should be to have a pointing calibrated start position (birdbath), if the beam is
mode, where joint 5 is in zero degrees, see figure 1b. broken or another reflector is to measured, the tracker
This gives the robot a chance to increase its base requires re-calibrating the reflector in the start
stiffness to some extent. One has to be cautious for position. The LTD800 however, uses an ADM
 Proceedings of the 35th ISR (International Symposium on Robotics) 23-26 March, 2004

(Absolute Distance Meter), (8),(9). The ADM enables equipped with an automatic hydro-mechanical Capto
the tracker to locate individual target reflectors chuck system. This enables the robot to interact with
without the need to measure from a calibrated origin flexible tooling modules presented by Kihlman and
position. The ADM can independently measure the Engström, 2002 (5), ordinary drilling machines and
absolute distance to any unknown reflector location, Orbital Drilling machines such as presented by
which simplifies re-initialising the interferometer. Kihlman et al., 2002 (7). The controller on the robot
Whereas the ADM is only used in initialising the used for the experiments was the S4Cplus version.
interferometer, it cannot itself be used for tracking.
4 COMMUNICATION
The LTD800 can have an additional camera, the T-
In order to connect a metrology system with a robot,
Cam, which is attached on top of the tracker unit. The
the robot needs to be able to communicate with the
T-Cam measures the orientation of a target. The
metrology system. ABB robots, which have been
accuracy of the LTD800 is ±10 ppm (µm/m) for static
used in this research, have today basically two
targets, and 20 ppm for moving targets. Distance
communication ports. One is serial port, which has
resolution is 1.26 µm and angle accuracy is 0.02 been a standard for communication with robots in
degrees. The angle accuracy is kept constant over the general for many years. Today exists also TCP/IP,
full measurement volume, through the use of a zoom which now has become a standard for communication
objective in The T-Cam. The zoom objective with robots. RS232 and TCP/IP has until now mainly
continuously maximizes the resolution from the been used for downloading robot programs from an
reflector targets in the camera picture. offline programming system. Presented in this paper,
TCP/IP has been used for synchronising a servo loop
3.2 The 6D-Reflector
on an external PC with a metrology system and the
To measure robot positions in 6 DOF a reflector was robot controller.
developed. The 6D-Reflector is a further
development of the T-Probe that is a commercial 4.1 WebWare
product from Leica Geosystems AG. The 6D- The communication with the ABB robot was
Reflector is always initiated with the ADM, since achieved through WebWare. WebWare is a driver
there is no birdbath available for the 6D-Reflector. package from ABB that uses ActiveX controls and
The 6D-Reflector comprises of an aluminium housing OPC (OLE Process Control) server to enable a
that is attached 10 LEDs and a prism. The LEDs network connected computer to manipulate RAPID
enables the T-Cam to measure the orientation of the program execution, RAPID variable data and I/O-
6D-Reflector. signals on the S4 controller.

4.2 emScon
For accessing measured data using the TCP/IP
protocol, emScon from Leica was used. emScon is a
tracker-programming interface for complete
integration with Leica Trackers. The emScon server
Male Capto is accessed over the network through conventional
Female Capto
socket communication. A call for measurement is
Figure 3: The Multi-purpose 6D-Reflector initiated, and a response is given. This execution can
either be performed synchronously, where the
The LEDs are positioned at different depths for the program is stopped until a measurement is sent back
camera to measure orientation. The LEDs are flashing to the client, or asynchronously where a trigger is
in infrared light and the camera is zooming in the 6D- activated when the data is sent back to the client. The
Reflector so that the LEDs are taking up the full LTD800, according to specification, is able to
picture. The laser beam is reflected back to the measure 6DOF in 100 Hz and can interpolate
tracker unit from a glass prism retro-reflector. The between measurements in 1000 Hz. To use
glass enables the beam to be +/- 50 degrees away measurements for feedback control however, requires
from the prism axis before contact is lost. The 6D- each measurement to be sent by emScon to the PC
Reflector housing has two ergonomically designed prior to updating the robot. To clarify this, the
handles when moving the 6D-Reflector manually. For emScon server is sending 4 packages with data per
attaching the 6D-Reflector a system called Capto C4 second. This means that the 100 measurements per
from the Company SANDVIK AB was used. The seconds are divided in 4 packages of 25
Capto system is generally used for attaching cutting measurements. For a feedback control loop, only 4
tools in NC-chucks. The repetitive accuracy of the measurements can be used for updating the robot
Capto C4 is 2 µm with a maximum load capacity up controller per second, hence the rest is just old data.
to 17 kN. This indicates that the bottleneck in the integration
now is the emScon server. Updating frequency in the
3.3 The Robot system is hence 4 Hz. For the applications presented
in this paper on the other hand, this update frequency
The robot is a standard Industrial Robot, the IRB4400 was enough to manage the processes. If however the
from ABB. The IRB4400 has a repetitive accuracy of robot needs to be updated at higher speeds, such as in
50 µm and a maximal payload of 60 Kg. The robot is
 Proceedings of the 35th ISR (International Symposium on Robotics) 23-26 March, 2004

compensating deflection in drilling, this speed would spikes sometimes up to 50 ms. It was clearly
not be enough. indicated in these tests that the network itself was not
the bottleneck, but instead the S4Cplus controller. If
the emScon server were to send data more times per
The LT-controller plus includes two independent
second, another issue would appear in the integration;
computers. One is emScon that runs on a Windows
Robots have their own controller with ramp-ups and
2000 operative system, which is not a real-time
brake patterns that will slow down the actual step-
system. The tracker processor is running on a real-
response time. For rapid update of the robot
time system and could support a high-speed interface.
manipulator another method would be required, such
It could be solved in two ways; either through a
as through shared memory communication directly
parallel interface using IEEE 1284 that would enable
with the robot controller.
data transfer with a very short delay and low
overhead. Transferring a measured point would with 4.4 Programming method
this method take only 100-200 microseconds.
Another method would be to use a 100Mbit/s or All robot activities were programmed in the Offline
1Gbit/s Ethernet with point-to-point connection, simulation/programming package V5Robotics/R12
using the UDP protocol. Measurements could then be from DELMIA. Since the robot in this research does
transferred within 1-2 milliseconds. Neither of these not operate like normal robots, the post-processor
methods is supported today, but it could be possible phase into RAPID code was not done in the OLP-
to accomplish. Changing communication method to module as normal. Instead the XML-code prior to this
real-time would as a consequence also require phase after all simulations and was downloaded to the
another platform for the Server PC, which today runs Server PC of the metrology-integration and
on a Windows 2000 operative system. Transferring interpreted there. This enabled the programming to be
measurements in real-time would be triggered at a fix performed on a more task-oriented approach. On the
rate based on a clock, or a trigger line, whereby robot existed only one program that was generic and
transferring of data is done with only a short delay. never changed. The Server PC executed different sub-
TCP/IP and emScon would still be used on a real- routines such as docking, drilling, fixture
time platform, but only for things such as setup of the configuration etc. The program execution on the
tracker, starting and initialising tracker and camera, Server PC manipulated, through WebWare, different
establish transformation parameter from the tracker to PERS (global) variables, reading and writing I/Os etc.
the object coordinate system etc. on the robot. WebWare does not support direct
manipulation of move commands. The generic
4.3 Integration program concept enabled this to be overridden.
The integration was implemented with a standard
TCP/IP network set-up. An Ethernet switch connects 5 CALIBRATION METHODS
the PC with the robot controller and the emScon
Before starting the execution of the metrology
server, see figure 4.
integration, the robot and its additional accessories
needs to be calibrated. This section is presenting
these methods. Figure 5 shows the transformations
between the different coordinate systems of the
integration.

Tr Tr
Re fl T

Tr Re fl
Rob T Rob
T TCP 0T
TCP 0

Refl
TCP0

Rob Re fl
T
Figure 4: The system architecture for the integration Chuck

Figure 5: The coordinate systems and transforms

Since the emScon server is limited to 4 updates per
second, the TCP/IP communication did not limit the In the method presented in this section the notation
speed. Delays using the TCP/IP protocol did not A
T for the 4 x 4 homogeneous transform is used to
B
affect the synchronisation speed at this time. IP-
describe coordinate systems and transformations (2).
networks however, are unreliable due to packet loss
For example, the homogeneous
etc., and is not a real-time communication platform. A
Tests on round trip time (RTT) were performed. The transformation BT describes the frame { B } relative
test results indicated that RTT was about 30 ms, with to the frame { A }, which when talking about
 Proceedings of the 35th ISR (International Symposium on Robotics) 23-26 March, 2004

transforms is interpreted as the coordinate { B } in the important to realize that this calibration will not affect
{ A } coordinate system. the final positional accuracy of the robot, but merely
the time to reach a high-accuracy position, since the
5.1 Robot chuck servo loop on the server PC will continue iterate until
The first step in the calibration was to calibrate the a position is reached within the specified tolerance
Re fl interval.
transformation ChuckT , which is where the chuck TCP
is positioned relative to the 6D-Reflector sitting next
Another method of calibration was also tested which
to the chuck. Calibration of the Capto TCP is most
again moves the robot to different configurations.
sensitive to avoid tolerance build-up, which results in
The kinematics equation to be solved is:
low absolute accuracy. The method is summarised as
Re fl 0 TCP 0 Re fl 1
the following: TCP 0 T ×TCP
TCP 0 T × Re fl 2 T =
Tr
Tr T × Re fl 2 T
1. Install the 6D-Reflector in the chuck using the
Where Refl1 and Refl2 refer to the 6D-Reflector
male Capto part on the 6D-Reflector
reading from two different robot positions.
2. Measure the 6D-location A TCP 0
TCP 0T refers to a robot move in end-effector co-
3. Install the 6D-Reflector in one of the
Re fl
attachments beside the chuck ordinates. The transform TCP 0T is built up from a
4. Measure the 6D-location B series of robot moves using the Powell optimisation
It is important to keep the metrology end-effector routine.
absolutely still during measurement. It is
recommended to remove the metrology/chuck end- 5.3 End-effector calibration
effector and rigidly attach it in a bench during this When manipulating a robot with end-effectors, the
calibration phase. When the chuck position is given TCP of the robot is often moved from TCP0 to the
from the tracker, this calibration is the only thing that end-effector tip. This enables the robot to rotate
will affect tolerance build-up. The transformation around the tip of the end-effector unit. This is
matrix is given from this equation: important for reaching high accuracy in the angular
Re fl domain. The question here is obvious: How is the tip
Chuck T = TrAT − TrBT
of the end-effector calibrated? Note that the
Tr in the equation is the tracker coordinate system. transformation presented in this section will be
The 6D-Reflector unit itself comprising the housing presented relative the Robot Chuck. This is because
and the male/female Capto was calibrated by Leica the implementation presented in this research is based
with an accuracy of 10 µm. on attaching end-effectors to the Capto Chuck, not
directly on TCP0. There are basically two different
5.2 Robot base and TCP0 methods that can be used. One of the methods is
selected depending much on the production scenario.
TCP0 (TCP zero) is the default Tool Center Point on
the robot. The transformation from TCP0 to 6D- Inline-calibration of End-effectors
Reflector is important in order to define new TCPs This method is based on the scenario where the end-
for end-effectors. This method is based on moving effector is already attached to the Robot Chuck and
the robot to different configurations, which will calibration of the end-effector TCP is to be calibrated.
supply data in a large equation system. The equation In this case, the robot obviously needs to be still, and
to solve is: the production process is stopped. This scenario is
Tr Rob
T ×TCP TCP 0 Tr realistic especially if for instance the offset of a
Rob 0 T × Re fl T = Re fl T
pressure foot is changed; hence the local Z-direction
This equation is easy to follow by looking in figure 5. is moved. In this research, this method has only been
Rob
T is achieved by reading values from the robot verified for a Drill End-effector; hence the rotation of
TCP 0
the XY-plane around Z was not considered.
controller. For each measurement taken from the
Tr
robot controller a measurement for T is taken
Re fl
Rob Tr
from the tracker, hence TCP 0T and T are
Re fl Tr Prism
Rob Bushing T
measured in pairs. After calibration run TCP 0 T and Drill
Tr Re fl bushing
Tr
T are constructed out of variables in an BushingT
Re fl
Tr Refl Cylindrical
optimisation algorithm implemented the software T
Re fl object
package MATLAB Optimisation Toolbox. The
optimisation is performed by minimizing the cost Figure 6: Calibrating an end-effector
function:
f =∑ Tr
TRob × Rob TTCP 0,i ×TCP 0 TRe fl − Tr TRe fl ,i The method described according to the following
n steps:
During tests, the value of the cost function was low,
and test runs indicated that the robot co-ordinate
system aligned with tracker coordinate system. It is
 Proceedings of the 35th ISR (International Symposium on Robotics) 23-26 March, 2004

1.
XY-plane: Measure the plane of the pressure- to the project manager of the ADFAST project, John
foot using a reflector ball Andersson. We would also like to thank SANDVIK
2. Z-direction: Measure a cylindrical object in the AB for showing great interest and providing to us the
same direction as the drill on the machine. In Capto System.
this case it is not important that the cylindrical
center is align with the drill Z-axis. 8 REFERENCES
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6 CONCLUSION Committee, Williamsburg Hospitality House,
This paper presented continuing research on Williamsburg, Virginia, July 8 – 12, 1996
Metrology-integrated Industrial Robots. The result
from tests and calibration showed that Industrial
Robots can reach extreme absolute accuracy down to
+/-50 µm if a metrology system is online with the
robot controller. Using TCP/IP cannot guarantee real-
time control. In order to reach higher productivity, a
platform that supports real-time control would be the
natural way to continue this research.

7 ACKNOWLEDGEMENTS
This work is part of the EU-founded project
ADFAST (Automation for Drilling, Fastening,
Assembly System and Tooling). Special thanks goes