WO2014042668A2

WO2014042668A2 - Automatic and manual robot work finder calibration systems and methods

Info

Publication number: WO2014042668A2
Application number: PCT/US2013/000146
Authority: WO
Inventors: Matthew E. TROMPETER
Original assignee: Trompeter Matthew E
Priority date: 2012-06-11
Filing date: 2013-06-10
Publication date: 2014-03-20
Also published as: WO2014042668A3

Abstract

The manual and automatic robot work finder calibration systems combine a visual datum reference tool with either a manual or automatic tool finder. Two different visual datum reference tools can be used with either an automatic or manual work finder. This technology enables the user to visually see a robotic reference frame, a frame in space that is relative to an industrial robot that is otherwise abstract. Enabling the user to visually see the robotic reference frame on the shop floor enables adjustment of the robotic frame to the shop floor and correction of a robotic path or off-line program to enhance accuracy. Two laser beams are emitted and intersect at a tool center point. The tool center point and the laser beams are then used to define a robotic reference frame. The technology improves cost and time factors in applications where absolutely accurate robots are not really necessary.

Description

AUTOMATIC AND MANUAL ROBOT WORK FINDER

CALIBRATION SYSTEMS AND METHODS

FIELD OF USE

The present invention relates to an automatic and a manual work finder calibration systems and methods for an industrial robot and, more particularly, to a calibration method for the industrial robot provided with an imaging device of a visual sensor for detecting a working tool and a working position.

BACKGROUND OF THE INVENTION

The sales of industrial robots that has been driven by the automotive industry is now moving into tasks as diverse as cleaning sewers, detecting bombs, and performing intricate surgery. The number of units sold increased to 120,000 units in 2010, twice the number as the previous year, with automotive, metal, and electronics industries driving the growth.

Prior approaches to calibrating robots use measuring devices that either measures the inaccuracies of the robots after the robot is built or devices which measure work pieces positions relative to the robots position prior to OLP's.

Some of the prior art includes:

U.S. Patent No. 7,979,159 (Fixell) discloses an invention which relates to a method and a system for determining the relation between a local coordinate system located in the working range of an industrial robot and a robot coordinate system. The method includes attaching a first calibration object in a fixed relation to the robot and determining the position of the first calibration object in relation to the robot. Then, locating at least three second calibration objects in the working range of the robot, a reference position for each of the second calibration objects in the local coordinate system can be determined by moving the robot until the first calibration object is in mechanical contact with each second calibration object. By reading the position of the robot when the calibration objects are in mechanical contact the relation between the local coordinate system and the robot coordinate system can be calculated.

U.S. Patent No. 7,945,349 (Svensson, et. al.) discloses an invention which relates to a method and a system for facilitating calibration of a robot cell including one or more objects and an industrial robot performing work in connection to the objects, wherein the robot cell is programmed by means of an off-line programming tool including a graphical component for generating 2D or 3D graphics based on graphical models of the objects. The system comprises a computer unit located at the off-line programming site and configured to store a sequence of calibration points for each of the objects, and to generate a sequence of images including graphical representations of the objects to be calibrated and the calibration points in relation to the objects, and to transfer the images to the robot, and that the robot is configured to display said sequence of images to a robot operator during calibration of the robot cell so that for each calibration point a view including the present calibration point and the object to be calibrated is displayed to the robot operator.

U.S. Patent No. 7,756,608 (Brogardh) discloses a method for calibration of an industrial robot including a plurality of movable links and a plurality of actuators effecting movement of the links and thereby of the robot. The method includes mounting a measuring tip on or in the vicinity of the robot, moving the robot such that the measuring tip is in contact with a plurality of measuring points on the surface of at least one geometrical structure on or in the vicinity of the robot, reading and storing the positions of the actuators for each measuring point, and estimating a plurality of kinematic parameters for the robot based on a geometrical model of the geometrical structure, a kinematic model of the robot, and the stored positions of the actuators for the measuring points.

What are needed are automatic and manual robotic tool finder systems and methods to improve cost and time factors in applications where absolutely accurate robots are not really necessary; examples including body-in-white (BIW) applications, resistance welding, material handling, and MIG welding. What are needed are an automatic and manual robotic tool finder system and method for using different robot tools on a shop floor without having to perform a recalibration for each tool.

The primary objective of the automatic and manual robotic tool finder systems and methods of the present invention is to provide a calibration method which is simpler to operate, results in improved precision, involves a lower investment cost, and entails lower operating costs.

Another objective of the automatic and manual robotic tool finder systems and methods of the present invention is to increase the accuracy of the off-line program and decrease robot teaching time, while also negating the need for the technician to "jog" the robot into position as the process is automated.

SUMMARY OF THE INVENTION

The automatic and manual robotic tool calibration systems and methods of the present invention address these needs and objectives.

This technology enables the user to visually see a robotic reference frame, a frame in space that is relative to an industrial robot, that is otherwise abstract and cannot be seen. Enabling the user to visually see the robotic reference frame on the shop floor will enable the user to adjust the robotic frame to the shop floor environment and, thereby, correct a robotic path or off-line program (OLP) to obtain accuracy.

The robotic tool calibration system and method of the present invention combines a visual datum reference tool with either a manual or automatic tool finder.

The visual datum reference tool includes two (2) laser positioned onto a work piece or tool, at a known location (a numerical control block or NAAMS mounting pattern) with the two laser beams intersecting at essentially at a ninety degree (90°) angle and continuing to project outward. The tool center point (TCP) of the robot defines the correct location of the robotic reference frame. To accomplish this, the robot TCP records a first point at the intersection of the two (2) laser beams. A second point is then recorded along the axis of the first laser beam. A third point is then recorded along the axis of the second laser beam. Once all three (3) points are known, the robotic reference frame is generated. The robotic reference frame is then used to adjust the angular position of the robot tool, which can involve adjusting roll, pitch and/or yaw of said robot tool. This method is applicable for all robotic processes, including but not limited to, spot welders, material handlers, and MIG welders, assembly, cutting, painting and coating, and polishing and finishing.

An alternate embodiment of the visual datum reference tool is a actually a modification of the "Robotic Work Object Cell Calibration System" by the same inventor (Matthew E. Trompeter) and is fully described in U.S. Patent Application Ser. No. 13/563,903; filed on August 1 , 2012. An "E-shaped" structure lays horizontally and is positioned at the center of a frame comprising a vertical frame member crossing a horizontal frame member. Two crossing laser beams are emitted from lasers mounted in the "E-shaped" structure. The modification is quite minor in that the leg of the "E- shaped structure" [25] opposing to where a second laser is mounted now includes an opening, enabling said laser beam to pass through unobstructed by said leg of said visual datum reference tool. The visual datum reference tool also includes four plane- projected lasers, one mounted at each frame member end. The laser planes can also be used to adjust for yaw, pitch, and roll of the robot tool.

The preferred embodiment of the manual robotic tool finder device of the present invention is used in conjunction with the "Robotic Work Object Cell Calibration Device, System, and Method" as described in PCT/US2012/000140 (Trompeter) filed on March 14^th, 2012, or the "Visual Datum Reference Tool" as described in U.S. Provisional Application No. 61 /689,643 (Trompeter) filed on June 11^th, 2012. The manual robotic tool finder device is preferably placed over the weld tips of a weld gun. The manual automatic robot work finder device of the present invention includes two intersecting passageways. The passageways are manually aligned with either the lasers emitted from either the robotic work object cell calibration device or with the visual datum reference tool. The manual automatic robot work finder device of the present invention is placed over the tool center point of either the robotic work object cell calibration device or the visual datum reference tool, the manual robotic tool finder device calibrating the robot work path. Either a manual robotic tool finder or an automatic robotic tool finder is then used with either visual datum reference tool to calibrate the robot and the work path.

For a complete understanding of the automatic and manual robotic tool finder systems and methods of the present invention, reference is made to the following summary of the invention detailed description and accompanying drawings in which the presently preferred embodiments of the invention are shown by way of example. As the invention may be embodied in many forms without departing from spirit of essential characteristics thereof, it is expressly understood that the drawings are for purposes of illustration and description only, and are not intended as a definition of the limits of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1A depicts a first perspective view of a first preferred embodiment of the visual datum reference tool for use with the automatic and manual robot work finder calibration systems and methods of the present invention, the visual datum reference tool having two beam-projecting lasers being used for aligning the tool center point with a calibration device.

FIGURE 1 B depicts a second perspective view of the preferred embodiment of the visual datum reference tool of FIGURE 1A.

FIGURE 1 C depicts a third perspective view of the preferred embodiment of the visual datum reference tool of FIGURE 1A mounted on an NC block or a NAAMS mounting.

FIGURE 2 depicts a perspective view of the visual datum reference tool of FIGURE 1A positioned on a fixture, with the robot being aligned to the tool center point of the visual datum reference tool.

FIGURE 3 depicts a perspective view of the visual datum reference tool of FIGURE 1A positioned on the fixture as shown in FIGURE 2, with the robot being aligned to a point in space along the x-axis of the first laser beam projected from the visual datum reference tool. FIGURE 4 depicts a perspective view of the visual datum reference tool of FIGURE 1A positioned on the fixture as shown FIGURE 2, with the robot being aligned to a point in space along the y-axis of the second laser beam projected from the visual datum reference tool.

FIGURE 5 depicts a perspective view of a second preferred embodiment of the visual datum reference tool for use with the manual and automatic robot work finder calibration systems and methods of the present invention, the visual datum reference tool having two beam-projecting lasers being used for aligning the tool center point with a calibration device.

FIGURE 6 depicts a perspective view of the visual datum reference tool of FIGURE 5 positioned on a fixture, with the robot being aligned to the tool center point of the visual datum reference tool.

FIGURE 7 depicts a perspective view of the visual datum reference tool of FIGURE 5 positioned on the fixture as shown in FIGURE 6, with the robot being aligned to a point in space along the x-axis of the first laser beam projected from the visual datum reference tool.

FIGURE 8 depicts a perspective view of the visual datum reference tool of FIGURE 5 positioned on the fixture as shown FIGURE 6, with the robot being aligned to a point in space along the y-axis of the second laser beam projected from the visual datum reference tool.

FIGURE 9 depicts a perspective view of a first preferred embodiment of a manual robotic tool finder for use with the manual robot work finder calibration systems and methods of the present invention.

FIGURE 10 depicts a perspective view of the preferred embodiment of the manual robotic tool finder of the FIGURE 9 from above with the upper and lower jaws separated.

FIGURE 11 depicts a perspective view of the preferred embodiment of the manual robotic tool finder of the FIGURE 9 from below with the upper and lower jaws separated. FIGURE 12 depicts a perspective view of the manual robotic tool finder of FIGURE 9, the manual robotic tool finder being mounted onto a weld gun.

FIGURE 13 depicts a perspective view of the manual robotic tool finder of FIGURE 9 used with the visual datum reference tool of FIGURE 5, the manual robotic tool finder being mounted onto the weld gun and positioned at the tool center point of the visual datum reference tool, the visual datum reference tool being mounted onto a fixture for use with the manual robot work finder calibration systems and methods of the present invention.

FIGURE 14 depicts a perspective view of the manual robotic tool finder of FIGURE 9 used with the visual datum reference tool of FIGURE 5 and as shown in FIGURE 13, the manual robotic tool finder being mounted onto the weld gun and positioned downstream of the laser beam being emitted from the center of the visual datum reference tool, the visual datum reference tool being mounted onto a fixture.

FIGURE 15 depicts a perspective view of the manual robotic tool finder of FIGURE 9 used with the visual datum reference tool of FIGURE 5 and as shown in FIGURE 13, the manual robotic tool finder being aligned with the laser beam normal to the laser beam being emitted from the center of the visual datum reference tool, while searching for a work path being projected by the robotic work object cell calibration tool.

FIGURE 16 depicts a perspective view of the manual robotic tool finder of FIGURE 9 mounted onto a weld gun being used with the visual datum reference tool of FIGURE 1A and positioned at the tool center point of said visual datum reference tool.

FIGURE 17 depicts a perspective view of the manual robotic tool finder of FIGURE 9 mounted onto a weld gun and as shown in FIGURE 16, while aligned with the 1^st laser beam projected by the visual datum reference tool of FIGURE 1A for use with the manual robot work finder calibration systems and methods of the present invention.

FIGURE 18 depicts a perspective view of the manual robotic tool finder of FIGURE 9 mounted onto a weld gun and as shown in FIGURE 16, while aligned with the 2^nd laser beam projected by the visual datum reference tool of FIGURE 1A for use with the manual robot work finder calibration systems and methods of the present invention.

FIGURE 19 depicts a perspective view of the preferred embodiment of the automatic robotic tool finder for use with the automatic robot work finder calibration systems and methods of the present invention.

FIGURE 20 depicts a perspective view of the automatic robotic tool finder of FIGURE 19 mounted onto a weld gun being used with the visual datum reference tool of FIGURE 1A, said automatic robotic tool finder being positioned at the tool center point of the visual datum reference tool.

FIGURE 21 depicts a perspective view of the automatic robotic tool finder of FIGURE 19 mounted onto a weld gun as shown in FIGURE 20 while aligned with a first laser projected by the visual datum reference tool of FIGURE 1A for use with the automatic robot work finder calibration systems and methods of the present invention.

FIGURE 22 depicts a perspective view of the automatic robotic tool finder of FIGURE 19 mounted onto a weld gun as shown in FIGURE 17 while aligned downstream with a second laser projected by the visual datum reference tool of FIGURE 6A for use with the automatic robot work finder calibration systems and methods of the present invention.

FIGURE 23 depicts a perspective view of a the automatic robotic tool finder of FIGURE 19 used with the visual datum reference tool of FIGURE 5, said automatic robotic tool finder being positioned at the tool center point of the visual datum reference tool.

FIGURE 24 depicts a perspective view of the automatic work finder calibration system of FIGURE 19 used with the visual datum reference tool of FIGURE 5 as shown in FIGURE 23, the manual robotic tool finder being mounted onto the weld gun and positioned downstream of the laser beam being emitted from the center of the visual datum reference tool, the visual datum reference tool being mounted onto a fixture for use with the automatic robot work finder calibration systems and methods of the present invention. FIGURE 25 depicts a perspective view of the automatic work finder calibration system of FIGURE 19 used with the visual datum reference tool of FIGURE 5 as shown in FIGURE 23, the manual robotic tool finder being aligned with the laser beam normal to the laser beam being emitted from the center of the visual datum reference tool, while searching for a work path being projected by the robotic work object cell calibration tool for use with the automatic robot work finder calibration systems and methods of the present invention.

DETAILED DECRIPTION OF THE PREFERRED EMBODIMENTS

The robotic tool calibration system and method of the present invention combines a visual datum reference tool with either a manual or automatic tool finder. The visual datum reference tool are depicted in FIGURES 1 through 8.

Referring now to the drawings, FIGURES 1A, 1 B, and 1C depict the preferred embodiment of the visual datum reference tool [10] of the present invention. The visual datum reference tool [10] preferably has two lasers [12 and 14] securely mounted therein, each laser emitting a laser beam [22 and 24, respectively] therefrom. The lasers are preferably mounted in the robotic datum/frame [28] of the visual datum reference tool [10] so that the laser beams {22 and 24] intersect each other at essentially right angles relative to each other. The two laser beams [22 and 24] are used for aligning the tool center point [26] with a calibration device on a robot tool [20].

The technology enables the user to visually see a robotic reference frame [35] (a frame in space that is relative to an industrial robot) that is otherwise abstract and cannot be seen. Enabling the user to visually see the robotic reference frame [35] on the shop floor will enable the user to adjust the robotic reference frame [35] to the shop floor environment and, thereby, correct a robotic path or off line program (OLP) to obtain accuracy.

The visual datum reference tool of the present invention [10] includes two (2) laser beams positioned onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAAMS mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [35]. To accomplish this, the robot will record a first point [26] at the intersection of the two (2) laser beams (see FIGURE 2). A second point [23] is then selected along the axis of the first laser beam [22] at a robotic path tag [75] (see FIGURE 3). A third point [25] is then selected along the axis of the second laser beam [24] at another robot path tag [75] (see FIGURE 4).

In other words, the robotic reference frame [35] is defined by the two intersecting laser beams [22 and 24]. Once all three (3) points [22, 24, and 26] are known, the robotic reference frame [35] is generated. The robotic reference frame is then used to adjust the angular position of the robot tool [20], which can involve adjusting either roll and yaw, roll and pitch, yaw and pitch, or roll yaw and pitch of said robot tool [20]. This method is applicable for all robotic processes, including but not limited to, spot welders, material handlers, and MIG welders, assembly, cutting, painting and coating, and polishing and finishing.

Using CAD simulation software, the CAD user selects a position on the tool that is best suited to avoid crashes with other tooling and for ease of access for the robot or end- of-arm tooling. The offline programs are then downloaded relative to the visual datum reference tool [10]. The visual datum reference tool [10] is then placed onto the tool or work piece in the position that is defined by the CAD user on the shop floor. The robot technician then manipulates the tool center point [26] of the robot tool [20] into the device and aligns it to the laser beams to obtain the difference between the CAD world and shop floor. This difference is then entered into the robot [38] and used to define the new visual datum reference tool center point [26]. This calibrates the offline programs and defines the distance and orientation of the tool, fixture [39], and peripheral.

The offline programming with the visual datum reference tool [10] on the fixture [39] enables the visual datum reference tool [10] to be touched up to the "real world position" of the fixture [39] relative to the robot. If the fixture [39] ever needs to be moved or is accidently bumped, simply touch up the visual datum reference tool [10] and the entire path shifts to accommodate. The first and second laser beams [22 and 24] are projected onto known features of the robot tool [20], and then used to calibrate the path of the robot tool [20] and measure the relationship of the fixture [39] relative to the robot tool [20].

The CAD user initially selects a position best suited on a tool or work piece to avoid crashes with other tooling and for ease of access for the robot or end-of-arm tooling. The visual datum reference tool of the present invention [10] preferably mounts onto a fixture [39] using a standard NAAMS hole pattern mount [34], The mounts are laser cut to ensure the exact matching of hole sizes for the mounting of parts.

The visual datum reference tool [10] has a zero point, a zero reference frame, and a zero theoretical frame in space, which is positioned on the fixture [39].

The visual datum reference tool [10] is placed onto the fixture [39], visually enabling the tool center point [26] of the weld gun to be orientated into the visual datum reference tool [10] obtaining the "real-world" relationship of the robot tool [20] to the fixture [39] while updating the visual datum reference tool [10] to this "real- world" position.

The visual datum reference tool of the present invention [10] requires that the position of the visual datum reference tool [10] correlate with the position of the robot tool [20] to calibrate the path of the robot tool [20] while acquiring the "real- world" distance and orientation of the fixture [39] relative to the robot tool [20].

The visual datum reference tool [10] calibration method positions the robot tool [20] with the calibration device and determines the difference.

The visual datum reference tool [10] is used to calibrate a "known" calibration device or frame (robotic simulation CAD software provided calibration device). The robotic calibration method of the present invention works by projecting laser beams to a known X, Y, and Z position and defining known geometric planes used to adjust the roll, yaw, and pitch of the robot tool [20] relative to the tool center point [26].

The laser is projected onto the robotic end of the robot arm tooling (weld guns, material handlers, MIG torches, etc.) where the user will manipulate the robot with end-of-arm tooling into these lasers to obtain the positional difference between the "known" off-line program (simulation provided calibration device) and the actual (shop floor) calibration device. The reverse is also true - for instance; a material handler robot can carry the visual datum reference tool [10] to a known work piece with known features.

The CAD model of the visual datum reference tool [10] is placed in the robotic simulation CAD world. The CAD user selects a position best suited on a tool or work piece to avoid crashes with other tooling and for ease of access for the robot or end- of-arm tooling. The off-line programs are then downloaded relative to this visual datum reference tool [10]. The visual datum reference tool [10] will be placed onto the tool or work piece in the position that was defined by the CAD user on the shop floor. The robot technician then manipulates the tool center point [26] into the device, aligning it to the laser beams to obtain the difference between the CAD world and shop floor. This difference is then entered into the robot and used to define the new calibration device, thus calibrating the off-line programs and defining the distance and orientation of the tool, fixture [39], peripheral, and other key components.

The visual datum reference tool [10] calibrates the paths to the robot while involving the calibration of the peripherals of the robot.

The visual datum reference tool [10] aids in the kitting; or reverse engineering; of robotic systems for future use in conjunction with robotic simulation software; enabling integrators the ability to update their simulation CAD files to the "real world" positions.

The technology uses existing body-in-white procedures, personnel computers and software and ways of communicating information amongst the trades.

FIGURE 5 depicts a second preferred embodiment of a visual datum reference tool [20]. An "E-shaped" structure is lays horizontally and is positioned at the center of a frame comprising a vertical frame crossing a horizontal frame.

The visual datum reference tool [20] is used to calibrate the work path of a robot tool based on a tool center point (point in space) [26]. The known point in space [26] is defined in three dimensions (X, Y, and Z) and relative to their rotational axes R_x (pitch), R_y (yaw), and R_z (roll).

The visual datum reference tool [20] includes a horizontal frame member [17] that includes a pair of opposing frame ends [32A and 32B], and a vertical frame member [18] that includes a pair of opposing frame ends [32C and 32D]. A plane-projecting laser [41 , 42, 43, and 44] is preferably disposed at each frame end [32A, 32B, 32C, and 32D], respectively, and a projected laser plane (not shown) is emitted from each of the plane-projecting lasers [41 , 42, 43, and 44], respectively.

Extending along the horizontal frame member [17] are three arms parallel which combine to form a squared "E-shaped" structure [25] which is horizontally aligned and generally centrally disposed relative to horizontal frame member [17] and vertical frame member [18]. The center arm (not numbered) of the E-shaped structure [25] is shorter than the two end arms [27A and 27B].

A first laser beam [22] is emitted from the shortened center arm of the "E-shaped" structure [25] disposed at the proximate center of the visual datum reference tool [20]. A second laser beam [24] is emitted from one of the arms [27B] of an E-shaped structure [25] and is directed into and through an opening 29 in the opposing arm [27A].

The first laser beam-[22] intersects the second laser beam [24] at the tool center point [26]. The first laser beam -[22] is essentially perpendicular and coplanar with the second laser beam [24], defined in three dimensions in terms of X, Y, and Z coordinates.

The "E-shaped" structure [25A] is positioned at the center of the horizontal frame member [17] and the vertical frame member [18], laser beam [24] is essentially coplanar with the two projected laser planes (not shown) emitted from the plane- projecting lasers [41 and 42] emitted from frame ends [32A and 32B]. Similarly, laser beam [22] is essentially coplanar with the two projected laser planes (not shown) emitted from the plane-projecting lasers [43 and 44] emitted from frame ends [32C and 32D]. The visual datum reference tool [20] is mountable onto a fixture [39] and enables a robot work path to be calibrated relative to the known point in space [26],

The plane-projecting lasers project the four projected laser planes (not shown) from the frame ends [32A, 32B, 32C, and 32D, respectively] of the visual datum reference tool [20]. The plane-projecting lasers (see FIGURE 6) are preferably red laser modules, having focused lines (3.5v-4.5v 16mm 5mw).

The laser beams [22 and 24] are focusable points that project the two laser beams emitted from the arm [26B] of the visual datum reference tool [20]. The laser beams [56 and 58] are red laser modules, having focusable dots (3.5v-4.5v 16mm 5mw).

The visual datum reference tool of the present invention [20] includes two (2) laser beams positioned onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAAMS mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [35]. To accomplish this, the robot will record a first point [26] at the intersection of the two (2) laser beams (see FIGURE 5). A second point [23] is then selected along the axis of the first laser beam [22] (see FIGURE 6). A third point [25] is then selected along the axis of the second laser beam [24] (see FIGURE 7).

In other words, the robotic reference frame [35] is defined by the two intersecting laser beams [22 and 24]. Once all three (3) points [22, 23, and 25] are known, the robotic reference frame [35] is generated. The robotic reference frame is then used to adjust the angular position of the robot tool [20], which can involve adjusting either roll and yaw, roll and pitch, yaw and pitch, or roll yaw and pitch of said robot tool [20]. This method is applicable for all robotic processes, including but not limited to, spot welders, material handlers, and MIG welders, assembly, cutting, painting and coating, and polishing and finishing.

FIGURES 9, 10 and 11 depict the manual robotic tool finder component of the present invention. The manual robotic tool finder [110] has an upper jaw [123] and a lower jaw [133]. A pair of spring grips [140A and 140B] positioned at the rear of the device enables the device to be opened and closed to gain access to the passageways. A pair of passageways [121 and 122] extend through each jaw normal to each other forming a pair of intersecting passageways [124 and 126] through said upper jaw [123] and a pair of passageways [134 and 136] through said lower jaw [133]. The manual robotic work finder [110] is placed over the tool center point [26] of the visual datum reference tool [10 or 20]. The manual robotic tool finder device [1 10] calibrates the robot work path. FIGURE 12 depicts the manual robotic tool finder [110] mounted in a robot tool [50].

FIGURES 13, 14, and 15 depict the first preferred embodiment of the manual robotic work finder calibration system [62A] of the present invention. The manual robotic tool finder [110] is mounted on a robot tool [30] being used with the visual datum reference tool [20] mounted on fixture [39]. The manual robotic tool finder [110] cooperatively engages with the visual datum reference tool [20], which defines a robotic reference frame [35] (a frame in space that is relative to an industrial robot) that is otherwise abstract and cannot be seen. The visual datum reference tool of the present invention [10] includes two (2) laser beams positioned onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAA S mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [35]. To accomplish this, the robot will record a first point [26] at the intersection of the two (2) laser beams (see FIGURE 13). A second point [23] is then selected along the axis of the first laser beam [22] (see FIGURE 14). A third point [25] is then selected along the axis of the second laser beam [24] (see FIGURE 15).

FIGURES 16, 17, and 18 depict the second preferred embodiment of the manual robotic work finder calibration system [62B] of the present invention. The manual robotic tool finder [110] is mounted on a robot tool [30] being used with the visual datum reference tool [20] mounted on fixture [39]. The manual robotic tool finder [110] cooperatively engages with the visual datum reference tool [20], which defines a robotic reference frame [35] (a frame in space that is relative to an industrial robot) that is otherwise abstract and cannot be seen. The visual datum reference tool of the present invention [10] includes two laser mounted onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAA S mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [35]. To accomplish this, the robot will record a first point [26] at the intersection of the two laser beams (see FIGURE 16). A second point [23] is then selected along the axis of the first laser beam [22] (see FIGURE 17). A third point [25] is then selected along the axis of the second laser beam [24] (see FIGURE 18).

FIGURE 19 depicts a perspective view of the preferred embodiment of the automatic robotic tool finder [70] for use with the automatic robot work finder calibration systems and methods of the present invention. FIGURE 16 depicts the automatic work finder calibration system [70] of the preferred embodiment of the present invention. In one preferred embodiment, there is a grid of LEDs [16] on all four sides of the alignment tool which will allow the robot to be calibrated to any of the LEDs [16]. In another preferred embodiment, there is a grid of LEDs [16] on two adjacent sides of the alignment tool which will enable the robot to be calibrated to any of the LEDs [16]. The automatic work finder calibration system [70] has an opening extending therethrough that is used for mounting the device over the weld tips of a weld gun or pin on an end-of-arm-tooling.

While a cube is shown, other preferred geometric shapes include parallelepipeds, spheres, cylinders, pyramids, cones, capsules, and ellipsoids. Spheres have an added advantage in that there are no edges and spaces between the LEDs, as is the case when flat or pointed geometric surfaces are used.

FIGURES 20, 21 , and 22 depict the first preferred embodiment of the automatic robotic work finder calibration system [64A] of the present invention. The automatic robotic tool finder [70] is mounted on a robot tool [30] being used with the visual datum reference tool [10] mounted on fixture [39]. The automatic robotic tool finder [70] cooperatively engages with the visual datum reference tool [10], which defines a robotic reference frame [35] that is otherwise abstract and cannot be seen. The visual datum reference tool [10] includes two lasers mounted onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAAMS mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [28]. To accomplish this, the robot will record a first point [26] at the intersection of the two laser beams (see FIGURE 20). A second point [23] is then selected along the axis of the first laser beam [22] (see FIGURE 21 ). A third point [25] is then selected along the axis of the second laser beam [24] (see FIGURE 22).

FIGURES 23, 24, and 25 depict the second preferred embodiment of the automatic robotic work finder calibration system [64B] of the present invention. The automatic robotic tool finder [70] is mounted on a robot tool [30] being used with the visual datum reference tool [20] mounted on fixture [39], The automatic robotic tool finder [70] cooperatively engages with the visual datum reference tool [10], which defines a robotic reference frame [35] that is otherwise abstract and cannot be seen. The visual datum reference tool [10] includes two lasers mounted onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAAMS mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [28]. To accomplish this, the robot will record a first point [26] at the intersection of the two laser beams (see FIGURE 23). A second point [23] is then selected along the axis of the first laser beam [22] (see FIGURE 24). A third point [25] is then selected along the axis of the second laser beam [24] (see FIGURE 25).

FIGURE 26 depicts a perspective view of a third preferred embodiment of the visual datum reference tool for use with the manual and automatic robot work finder calibration systems and methods of the present invention, the visual datum reference tool [120] having two beam-projecting laser beams [22 and 24] being used for aligning the tool center point with a calibration device. In this embodiment, one of the arms of the E-shaped structure [27C] is truncated enabling laser beam [24] to extend beyond the visual datum reference tool [120], unimpeded.

The visual datum reference tool [120] is used to calibrate the work path of a robot tool based on a tool center point (point in space) [26]. The known point in space [26] is defined in three dimensions (X, Y, and Z) and relative to their rotational axes R_x (pitch), R_y (yaw), and R_z (roll).

The visual datum reference tool [120] includes a horizontal frame member [17] that includes a pair of opposing frame ends [32A and 32B], and a vertical frame member [18] that includes a pair of opposing frame ends [32C and 32D]. A plane-projecting laser [41 , 42, 43, and 44] is preferably disposed at each frame end [32A, 32B, 32C, and 32D], respectively, and a projected laser plane (not shown) is emitted from each of the plane-projecting lasers [41 , 42, 43, and 44], respectively.

Extending along the horizontal frame member [17] are three arms parallel which combine to form a squared "E-shaped" structure [25B] which is horizontally aligned and generally centrally disposed relative to horizontal frame member [17] and vertical frame member [18]. A first last laser [22] is emitted by a laser disposed in the center arm of the E-shaped structure [25B]. A second laser beam [24] is emitted from one of the arms [27A] and is directed unimpeded past the visual datum reference tool [120].

The first laser beam-[22] intersects the second laser beam [24] at the tool center point [26]. The first laser beam-[22] is essentially perpendicular and coplanar with the second laser beam [24], defined in three dimensions in terms of X, Y, and Z coordinates.

The "E-shaped" structure [25B] is positioned at the center of the horizontal frame member [17] and the vertical frame member [18], laser beam [24] is essentially coplanar with the two projected laser planes (not shown) emitted from the plane- projecting lasers [41 and 42] emitted from frame ends [32A and 32B]. Similarly, laser beam [22] is essentially coplanar with the two projected laser planes (not shown) emitted from the plane-projecting lasers [43 and 44] emitted from frame ends [32C and 32D]. The visual datum reference tool [120] is mountable onto a fixture [39] and enables a robot work path to be calibrated relative to the known point in space [26].

FIGURES 27, 28, and 29 depict the third preferred embodiment of the manual robotic work finder calibration system [62C] of the present invention. The manual robotic tool finder [110] is mounted on a robot tool [30] being used with the visual datum reference tool [20] mounted on fixture [39]. The manual robotic tool finder [110] cooperatively engages with the visual datum reference tool [20], which defines a robotic reference frame [35] (a frame in space that is relative to an industrial robot) that is otherwise abstract and cannot be seen. The visual datum reference tool of the present invention [10] includes two laser mounted onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAAMS mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [35]. To accomplish this, the robot will record a first point [26] at the intersection of the two laser beams (see FIGURE 27). A second point [23] is then selected along the axis of the first laser beam [22] (see FIGURE 28). A third point [25] is then selected along the axis of the second laser beam [24] (see FIGURE 29).

FIGURES 30, 31 , and 32 depict the third preferred embodiment of the automatic robotic work finder calibration system [64C] of the present invention. The automatic robotic tool finder [70] is mounted on a robot tool [30] being used with the visual datum reference tool [10] mounted on fixture [39]. The automatic robotic tool finder [70] cooperatively engages with the visual datum reference tool [10], which defines a robotic reference frame [35] that is otherwise abstract and cannot be seen. The visual datum reference tool [10] includes two lasers mounted onto a work piece or tool, at a known location with the two laser beams [22 and 24] intersecting at essentially a 90° angle and continuing to project outward. The mounting is preferably a numerical control block or a NAAMS mounting pattern [34]. The tool center point [26] of the robot defines the correct location of the robotic reference frame [28]. To accomplish this, the robot will record a first point [26] at the intersection of the two laser beams (see FIGURE 30). A second point [23] is then selected along the axis of the first laser beam [22] (see FIGURE 31 ). A third point [25] is then selected along the axis of the second laser beam [24] (see FIGURE 32).

The automatic and manual robot work finder calibration systems and methods of the present invention [10] are compatible with robotic simulation packages, including but not limited to, "Robcad®" which is a registered trademark of Tecnomatix Technologies Ltd., "Delmia®" which is a registered trademark of Dassault Systemes, Roboguide® which is a registered trademark of Fanuc Ltd. Corp., and "RobotStudio®" which is a registered trademark of ABB AB Corp. CAD software.

Throughout this application, various Patents and Applications are referenced by number and inventor. The disclosures of these Patents/Applications in their entireties are hereby incorporated by reference into this specification in order to more fully describe the state of the art to which this invention pertains. It is evident that many alternatives, modifications, and variations of the automatic and manual robotic tool finder devices and method of the present invention of the present invention will be apparent to those skilled in the art in light of the disclosure herein. It is intended that the metes and bounds of the present invention be determined by the appended claims rather than by the language of the above specification, and that all such alternatives, modifications, and variations which form a conjointly cooperative equivalent are intended to be included within the spirit and scope of these claims.

PARTS LIST . Visual datum reference tool (1^st embodiment). First laser

. Second Laser

. LEDs

. Horizontal frame member

. Vertical frame member

. Visual datum reference tool (2^nd embodiment). First laser beam

. Second Point

. Second laser beam

. Third Point

A. E-shaped structure with opening

B. E-shaped structure with truncated arm. Tool center point

A. E-shaped member arm w/ laser

B. E-shaped member arm w/ opening

C. E-shaped member truncated arm

. Robotic datum/frame

. Opening

. Robot tool

A, 32B, 32C, and 32D Frame ends

. Robot

. Fixture

. Visual datum reference tool

. 42, 43, and 44 Plane-projecting lasers 46. Wedge

47. NAAMS mount

48. Robotic datum /frame

50. Robot

60. Tool center point

62A. Manual robotic work finder calibration system (1^st embodiment) 62B. Manual robotic work finder calibration system (2^nd embodiment) 62C. Manual robotic work finder calibration system (3^rd embodiment) 64A. Automatic robotic work finder calibration system (1^st embodiment) 64B. Automatic robotic work finder calibration system (2^nd embodiment) 64C. Automatic robotic work finder calibration system (3^rd embodiment) 70. Automatic robot tool finder

75. Robot path tags

110. Manual robotic tool finder

120. Visual datum reference tool (3^rd embodiment)

121. Laser beam alignment hole #1

122. Laser beam alignment hole #2

123. Upper jaw

124. Upper jaw laser beam alignment passageway #1

126. Upper jaw laser beam alignment passageway #2

133. Lower jaw

134. Lower jaw laser beam alignment passageway #1

136. Lower jaw laser beam alignment passageway #2

Claims

CLAIMS I claim:

1. An automatic robot work finder calibration system, said system comprising: a. a visual datum reference tool, having a first and second laser, said first laser emitting a first laser beam, said second laser emitting a second laser beam, said first laser intersecting said second laser at a tool contact point; and b. an automatic tool finder having mounting means for retaining said calibration device onto a robot tool; said automatic tool finder having a plurality of LEDs mounted thereon, said plurality of LEDs in close prose proximity to each other, an LED being illuminated when struck by a laser.

2. The automatic robot work finder calibration system of Claim 1 , whereby said first and second laser beams intersect at essentially a ninety degree angle.

3. The automatic robot work finder calibration system of Claim 1 , whereby, adjustments of yaw, pitch, and roll of said robot tool are enabled.

4. A method for calibrating a robot work path deploying a visual datum reference tool in combination with an automatic tool finder, said visual datum reference tool having a frame, said frame, in use, emitting first and second laser beams, said first laser beam intersecting said second laser beam at a tool center point, said method comprising: a. aligning the tool center point to the beam projecting lasers attached to said visual datum reference tool by use of a robot control unit; b. aligning said tool center point with a processor to said beam projecting lasers on said robot tool; and c. positioning said automatic tool finder on either said first or said second laser beam, said automatic tool finder having a plurality of LEDs mounted thereon, said plurality of LEDs in close prose proximity to each other, an LED being illuminated when struck by a laser; whereby, upon illumination of said LEDs the LEDs transmit feedback advising that the automatic robotic tool finder is in alignment.

5. A manual robot work finder calibration system, said system comprising: a. a visual datum reference tool, having a first and second laser, said first laser emitting a first laser beam, said second laser emitting a second laser beam, said first laser intersecting said second laser at a tool contact point; and b. a manual tool finder having a first passageway and a second passageway that intersects said first passageway, and mounting means for retaining said manual tool finder onto a robot tool, said first passageway enabling said first laser beam to pass through said manual robotic reference tool, said second passageway enabling said second laser beam to pass through said manual robotic reference tool.

6. The manual robot work finder calibration system of Claim 5, whereby said second passageway intersects said first passageway.

7. The manual robot work finder calibration system of Claim 5, whereby said first and second laser beams intersect at essentially a ninety degree angle.

8. A method for calibrating a robot tool deploying a visual datum reference tool, said visual datum reference tool emitting a first and second laser beam, said first laser beam intersecting said second laser beam at a tool center point, said calibration method comprising:

a. securely mounting said visual datum reference tool;

b. identifying a first reference point, said first reference point being positioned at said tool center point;

c. identifying a second reference point along said first laser beam, said second reference point being positioned at a site other than at said tool center point; d. identifying a third reference point along said second laser beam, said third reference point being positioned at a site other than at said tool center point; and e. generating a robotic reference frame that includes said first, second, and third reference points, said robotic reference frame enabling adjustment of an angular position of said robot tool relative to said tool center point.

9. The method of Claim 8, further comprising securely retaining a manual robotic reference tool to said robot tool to enable said generating of said robotic reference frame, said manual tool finder having a first passageway and a second passageway, said second passageway intersecting intersects said first passageway, said first passageway enabling said first laser beam to pass through said manual robotic reference tool, said second passageway enabling said second laser beam to pass through said manual robotic reference tool.

10. The method of Claim 8, further comprising securely retaining an automatic tool finder having mounting means for retaining said calibration device onto a robot tool, said automatic tool finder having a plurality of LEDs mounted thereon, said plurality of LEDs in close prose proximity to each other, an LED being illuminated when struck by a laser.

11. The method of Claim 8, whereby said first and second laser beams intersect at essentially a ninety degree angle.

12. A visual datum reference tool for calibrating a robot tool, comprising:

a. a first laser beam emitted from said visual datum reference tool; and b. a second laser beam emitted from said visual datum reference tool, said second laser beam intersecting said first laser beam at a tool center point; c. a robotic reference frame defined by a first point disposed at said tool center point, a second point disposed along said first laser beam other than at said tool center point, and a third point disposed along said second laser beam other than said tool center point; wherein one or more angular positions of said robot tool are adjustable relative to said robotic reference frame.

13. A visual datum reference tool for calibrating a robot tool, comprising:

a. a first laser beam emitted from said visual datum reference tool, said first laser beam having a path; and b. a second laser beam emitted from said visual datum reference tool, said secon laser beam having a path, said second laser beam intersecting said first laser beam at a tool center point; c. a robotic reference frame defined by a first point disposed at said tool center point, a second point disposed along said first laser beam other than at said tool center point, and a third point disposed along said second laser beam other than said tool center point;

wherein once emitted, said first and said second laser beams proceed unobstructed by any portion of said visual datum reference tool.

14. The visual datum reference tool of Claim 13, whereby said first and second laser beams intersect at essentially a ninety degree angle.

15. A device for calibrating a robot work path, said device comprising:

a. mounting means for retaining said calibration device onto a robot tool; and b. a plurality of LEDs mounted thereon, said plurality of LEDs in close prose proximity to each other, each of said LEDs being illuminated when struck by a laser;

whereby, upon illumination of said LEDs by said laser, a user may align said robot relative to a point in space.

16. A robot calibration device comprising: a. a first passageway for enabling a first laser beam to pass through said device; b. a second passageway for enabling a second laser beam to pass through said device, said second passageway intersecting said first passageway; and c. mounting means for retention onto a robot tool; whereby said robot calibration device includes a closed position and an open position enabling access to said first and said second passageway.

17. A device for calibrating a robot work path, said device comprising: a. mounting means for retaining said calibration device onto a robot tool; and b. a plurality of LEDs mounted thereon, said plurality of LEDs in close prose proximity to each other, each of said LEDs being illuminated when struck by a laser; whereby, upon illumination of said LEDs by said laser, a user may align said robot tool relative to a point in space.

18. An automatic robot work finder calibration method, said method being used for calibrating a robot work path deploying a visual datum reference tool and an automatic tool finder, said visual datum reference tool having a frame, said frame, in use, emitting first and second laser beams, said first laser beam intersecting said second laser beam at a tool center point, said method comprising:

a. aligning the tool center point to the beam projecting lasers attached to said visual datum reference tool by use of a robot control unit;

b. aligning said tool center point with a processor to said beam projecting lasers on said robot tool; and

whereby said automatic tool finder includes a plurality of LEDs mounted thereon, said plurality of LEDs being in close prose proximity to each other; and whereby, upon illumination by said first or said second laser beam, one of said LEDs transmits feedback advising that the automatic robotic tool finder is in alignment.

19. An automatic tool finder for calibrating a robot work path, said automatic tool finder including a multiplicity of LEDs mounted at least one surface; whereby said automatic tool finder is cooperatively engaged with a laser emitting device; and whereby, upon illumination of said LEDs, the LEDs transmit feedback advising that the laser emitting device is in alignment.

20. A manual tool finder comprising:

a. a first passageway;

b. a second passageway that intersects said first passageway; and

c. mounting means for retaining said manual tool finder onto a robot tool;

whereby said manual tool finder includes a closed position and an open position, said open position enabling said first and second passageways.

21 . A system for calibrating a robot work path deploying a visual datum reference tool, said visual datum reference tool having a frame, said frame, in use, emitting first and second beam-projecting lasers, said first beam-projecting laser intersecting said second beam-projecting laser at a tool center point comprising:

a. means for aligning the tool center point to the beam projecting lasers attached to said visual datum reference tool by use of a robot control unit;

b. means for aligning said tool center point with a processor to said beam projecting lasers on said robot tool; and

wherein an angular position of said robot tool are adjustable relative to said robotic reference frame.

22. A method for calibrating a robot work path deploying a visual datum reference tool in combination with an automatic tool finder, said visual datum reference tool having a frame, said frame, in use, emitting first and second laser beams, said first laser beam intersecting said second laser beam at a tool center point, said method comprising: a. aligning the tool center point to the beam projecting lasers attached to said visual datum reference tool by use of a robot control unit; b. aligning said tool center point with a processor to said beam projecting lasers on said robot tool; and whereby, upon illumination, said LED transmits feedback advising a processor that the automatic robotic tool finder is in alignment.

23. A visual datum reference tool for calibrating a robot tool, comprising: a. a first laser beam emitted from said visual datum reference tool; and

b. a second laser beam emitted from said visual datum reference tool, said second laser beam intersecting said first laser beam at a tool center point; c. a robotic reference frame defined by a first point disposed at said tool center point, a second point disposed along said first laser beam other than at said tool center point, and a third point disposed along said second laser beam other than said tool center point;

wherein either said first or said second laser beam is unobstructed by any portion of said visual datum reference tool.