A Combined Calibration Method for Workpiece Positioning in Robotic Machining Systems and a Hybrid Optimization Algorithm for Improving Tool Center Point Calibration Accuracy

作     者：Hao, Daxian Zhang, Gang Zhao, Huan Ding, Han 

作者机构：Huazhong Univ Sci & Technol State Key Lab Intelligent Mfg Equipment & Technol Wuhan 430074 Peoples R China Huazhong Univ Sci & Technol Wuxi Res Inst Wuxi 214174 Peoples R China 

出 版 物：《APPLIED SCIENCES-BASEL》 (Appl. Sci.)

年 卷 期：2025年第15卷第3期

页      面：1033-1033页

核心收录：

基　　金：National Natural Science Foundation of China Pre-research Project on Leading Technologies of Wuxi Industry Innovation Research Institute [XD23018] 51535004 

主　　题：robotic machining hybrid optimization algorithm sphere-to-sphere TCP calibration combined calibration 

摘      要：This paper addresses the machining requirements for large aerospace structural components using robotic systems and proposes a method for rapid workpiece positioning that combines the simplicity of vision-based positioning with the precision of contact-based methods. To enhance the accuracy of robot calibration, a novel approach utilizing a ruby probe for sphere-to-sphere contact calibration of the Tool Center Point (TCP) is introduced. A robot contact calibration model is formulated, transforming the calibration process into a nonlinear least squares (NLS) optimization problem. To tackle the challenges of NLS optimization, a hybrid LM-D algorithm is developed, integrating the Levenberg-Marquardt (L-M) and DIviding RECTangle (DIRECT) algorithms in an iterative process to achieve the global optimum. This algorithm ensures computational efficiency while maximizing the likelihood of finding a globally optimal solution. An iterative convergence termination criterion for TCP calibration is established to determine global convergence, further enhancing the algorithm s efficiency. Experimental validation was performed on industrial robots, demonstrating the proposed algorithm s superior performance in global convergence and iteration efficiency compared to traditional methods. This research provides an effective and practical solution for TCP calibration in industrial robotic applications.