Kinematic Calibration Manual for CB3

Copyright 2009 – 2016 Version 0.9.4

Contents
1 Plate Calibration 1
1.1 Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Accessing the Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Measuring Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5.1 Calibration Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.2 Debugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.3 Applying the Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Reset Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Dual Robot Calibration 9

2.1 Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Mounting the Robots to the Calibration Horse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Accessing the Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Network Connection Between the Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4.1 Master/Slave Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.2 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Mounting the UR Dual Robot Calibration Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 Measuring Positions and Calibration Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Applying the Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8.1 Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.8.2 Reset Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Appendices 21

A Calibration Plate 21

B Dual Robot Tools 22

C Robot DH Parameter 23
C.1 UR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C.2 UR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C.3 UR10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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 1. Plate Calibration

1 Plate Calibration
This user manual goes through the calibration method for the kinematics, implemented on the Universal Robots
controller from software version 1.4. The manual is organised as a step by step tutorial.

Figure 1.1: Robot mounted on a plate with holes to align the robot tool flange.

CAUTION:
It is important to point out that not all calibrations are good calibrations. Please pay attention
to the generated statistics before saving the result of the calibration. If a calibration is not
performed with care, the robot may become inaccurate.

1.1 Required Equipment

The method is based on the assumption that it is possible to fixate the tool in multiple positions with the tool
flange parallel to the plane. In this tutorial we use a stiff plate with holes at known positions. The holes fits the
tool flange as displayed in Figure 1.1 (see details in Appendix A).

1
1. Plate Calibration

1.2 Accessing the Functionality

The starting point for the steps of the tutorial is a screen that looks like Figure 1.2.
The steps are as follows:

(1) The functionality can be found in the Expert Mode on the controller screen by pressing the "Kinematics
Calibration" button as illustrated in Figure 1.2.

(2) This enables a new tab called "Calibration" in the normal program mode. In this tab three cases can be
chosen, see Figure 1.3.

(a) Plate Calibration

Calibrate the robot by known positions on plates. Press this button to begin the calibration proce-
dure.
(b) Load an existing calibration
Makes it possible to load a previously saved calibration.

1
2a
2b

Figure 1.2: Select "Kinematics Calibration" in "Ex- Figure 1.3: Select "Plate Calibration" to select this
pert Mode" to get access to the calibration function- method.
ality.

2
 1. Plate Calibration

1.3 Measuring Positions

Multiple metal plates with a number of holes can be used. Add a plate to start adding positions.
(3) Add the first plate for the positions.

(4) Add the first position to the selected plate by pressing "Add new position".

3 4

Figure 1.4: Add a plate for the hole positions. Figure 1.5: Select "Add new positions" to add a posi-
tion to the selected plate.

(5) Insert the x , y , z coordinate relative to the plate for the position, see Figure 1.6.

(6) Move the related robot configuration by pressing "Teach new position", see Figure 1.6.

(7) Teach the robot to the correct position and pressing "OK" to complete one position, see Figure 1.7.

(8) To continue adding multiple positions pressing "Add new position", see Figure 1.6.

10

5 (X,Y,Z)
15

8 7

Figure 1.6: The property screen for the selected posi- Figure 1.7: Move the robot to the correct position


tion. Insert the x , y , z coordinate, teach the related and press "OK".
robot configuration. The screen has also a button to
add additional positions.

(9) Step no.: 5 to 8 is repeated until enough positions are added.

(10) Before starting on the calibration part it is recommenced to save the collected data. This is done by
pressing on the disk in the top left corner. Please note that the save function in the file menu save robot
programs and not calibrations and therefore can not be used, see Figure 1.6.
The configuration used in the calibration needs to be as distributed as possible on the plate but also in
the configuration space of the robot. Ensure that all the combinations of both elbow and wrist up and down
solutions are used, see Figure 1.8.
It is recommended that a full calibration at least includes 30 positions on each plate. To add an additional plate
select the top of the tree item "Positions" on the left and repeat the steps from 3.

3
1. Plate Calibration

Figure 1.8: Configuration need to be used.

4
 1. Plate Calibration

1.4 Calibration
Now all the needed positions for the calibration are added to the tree. In this example 26 Positions on one plate
are used.

(11) Select the top of the tree item "Positions" on the left to be able to select the level of calibration, see
Figure 1.9.

(a) Offset angles

This level calibrates the offset angles for the shoulder, elbow, wrist 1 and wrist 2. The method does
not provide enough information to calibrate the base and wrist 3.
(b) Partially
This level calibrates more parameters than 11a using other deviations than offset angles. It is not a
full calibration, but as full as the nature of the method allow it to be.

(12) The calibration is started from the "Calibration" tab, see Figure 1.10.

(13) Start the calibration by press "Make Calibration", see Figure 1.10.

11
12
13
11a
11b

Figure 1.9: Select the top of the tree item on the left Figure 1.10: Select the calibration tab and press
to be able to select the level of calibration. "Make Calibration" to start the calibration.

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1. Plate Calibration

1.5 Evaluation
(14) After the calibration has been performed the results needs to be evaluated to ensure that the calibration is
successfully.

The results from the calibration are the parameters displayed in the "Parameter overview" tab and the
calculated statistics of the archived precision for the given positions. The last part is displayed lower part of
Figure 1.11 and is used to evaluate the calibration.
The calculated statistics is divided into two groups: a) "Measurement data" which is statistics on positions
used in the calibration and b) "Evaluation data" which is statistics that evaluates the quality of the calibration
result.

18
17
19

14

Figure 1.11: The calibration is done and the result Figure 1.12: In the "Parameter overview" can the
needs to be evaluated. Afterwards it is possible to try identified parameters seen.
the new parameters and apply them to the robot.

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 1. Plate Calibration

1.5.1 Calibration Statistics

An example of the printed statistics:
1 ##############
2 I: 118
3 m: 0.000292995
4 Measurement data[20] error:
5 Mean: pos[m] ( 0.000175164, 0.000134324, 0.00027655 ) rot[rad] ( 0.00348157 )
6 StdDev: pos[m] ( 0.000218127, 0.000201774, 0.000344546 ) rot[rad] ( 0.00428109 )
7 Max: pos[m] ( 0.000518104, 0.000596791, 0.000853992 ) rot[rad] ( 0.00936474 )
8 Q range: [ 10.3565, 2.10395, 4.97534, 4.41847, 6.28554, 0.478753 ]
9 Evaluation data[6] error:
10 Mean: pos[m] ( 0.000171146, 0.00019818, 0.000210623 ) rot[rad] ( 0.00212999 )
11 StdDev: pos[m] ( 0.000221324, 0.00023433, 0.000267463 ) rot[rad] ( 0.00274118 )
12 Max: pos[m] ( 0.000405676, 0.000459457, 0.000443527 ) rot[rad] ( 0.00568077 )
13 Q range: [ 10.4986, 1.73156, 4.66844, 4.85263, 3.14473, 0.479093 ]
Listing 1.1: Example of printed statistics for a partially calibration

Explanation of line number:

1: This line is used to indicate that the calibration is running. Not important.

2: The number of used iterations finding the solution. Not important.

3: The sum of the calibrations residual error. Not important for the normal user.

4 to 8: The statistics for the positions used in the calibration. In this case the calibration is based on 20
positions.

9 to 13: The statistics for the positions reserved for evaluation only. In this case 6 positions. If there is a
large difference between the results of the evaluation and the measurement data, the calibration was not
successful and the positions needs to be verified.

5 and 10: The mean error. First with position error as a vector(x,y,z) followed by the rotation error.

6 and 11: The standard deviation of the error. It is formatted like the mean error.

7 and 12: shows the maximum error in the data. It is formatted like the mean error.

8 and 13: is the range of the used robot configuration. The range gives an indication of how well the
measurements are distributed.

The printed statistics is also saved in calibration.log file.

1.5.2 Debugging
To pinpoint the source for the maximum error, each position’s contribution to the residual error is displayed in
the position property screens, see Figure 1.6.

(15) If the evaluation was not successful: Examine that the correct coordinates were used in the defined
calibration points.

(16) If the configuration is too monotone: Add additional positions.

1.5.3 Applying the Calibration

When a satisfied calibration has been obtained it is recommended to try the new parameters before they are
stored permanently.

(17) Try the new calibration without saving them as the default by press "Use Calibration", see Figure 1.11.

The current default kinematics can be reloaded with the "Reload default". This button is not a "load factory
default" button. So please be aware of the quality of the calibration before applying them as permanently.

(18) The found parameters can be viewed in the "Parameter overview" tab, see Figure 1.12.

(19) Save the calibration for future use by pressing "Save as default", see Figure 1.11.

(20) The Robot is know calibrated.

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 1. Plate Calibration

1.6 Reset Calibration

The kinematic calibration can be removed by deleting the /root/.urcontrol/calibration.conf file, placed together
with the other configurations. It can also be removed by manually replace all the decimal and hex numbers, in
the configuration files, to zeros like in Listing 1.2.
1 [mounting]
2 delta_theta = [ 0, 0, 0, 0, 0, 0]
3 delta_a = [ 0, 0, 0, 0, 0, 0]
4 delta_d = [ 0, 0, 0, 0, 0, 0]
5 delta_alpha = [ 0, 0, 0, 0, 0, 0]
6 joint_checksum = [ 0x0, 0x0, 0x0, 0x0, 0x0, 0x0]
7 calibration_status = 0 # 0 == notInitialized / 1 == notLinearised / 2 == Linearised
8 joint_raw_offset = [ 0x0, 0x0, 0x0, 0x0, 0x0, 0x0]
9 joint_selftest_data_crc = [ 0x0, 0x0, 0x0, 0x0, 0x0, 0x0]
Listing 1.2: calibration.conf file filled with zeros

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 2. Dual Robot Calibration

2 Dual Robot Calibration

This manual is a step-by-step tutorial for integrators that describes how to perform Dual Robot Calibration of
the kinematics. The method can be used on Universal Robots—with Software version 3.0.16000 or later version.

The method is patented pending under the patentCalibration and Programming of Robots, Søe-Knudsen,
Rune (inventor); Petersen, Henrik Gordon (inventor); Østergård, Esben Hallundbæk (inventor), IPC: B25J9/16,
Patent number: EP2012/068337, September 18, 2012. International Publication number WO 2013/045314 A1.

Figure 2.1: The Dual Robot Calibration method.

CAUTION:
Stay clear of the robot when using Dual Robot Calibration.

CAUTION:
Not all calibrations are good calibrations. Please pay attention to the generated statistics before
saving the result of the calibration. If a calibration is not performed with care, the robot may
become inaccurate.
The method requires a Dual Robot Calibration kit from Universal Robots (purchase number: 185500) and
one pair of UR3, UR5 or UR10 robots, respectively, with a CB3 control box. The robot bases are connected with
the Calibration Horse and the robot tools are connected by the Tool Connector, see Figure 2.1. This creates
a closed chain where the distance between the bases and the tools are fixed to known distances. When the
robots has been connected it can perform a number of measurements from coordinated movements to different
positions. This creates a set of data which creates a mathematical foundation for determining the robot arm
lengths and link rotations of the robots, i.e. the Denavit-Hartenberg parameters.

9
2. Dual Robot Calibration

2.1 Required Equipment

The method requires a Dual Robot Calibration Kit from Universal Robots (purchase number: 185500) and one
pair of UR3, UR5 or UR10 robots with control box CB3. The robot bases are connected with a device and the
robot tools are connected by a device (Appendix B). This creates a closed chain where the distance between the
bases and the tools are fixed to known distances. In addition, the calibration horse, (Figure 2.2), have holes with
threads at the bottom for temponary and long term storage of screws.
Please note that the UR3, UR5 and UR10 are mounted differently on the Calibration Horse and that their
cables are pointing toward each other, as illustrated in Figure 2.2.
UR10

UR5

UR3
Cable

UR10
Cable
UR3

UR5
Figure 2.2: A sketch of the Dual Robot Calibration Horse and where the UR3, UR5 or UR10 robot can be mounted

To complete the assembly, mount the two handles at each end of the Calibration Horse with two M8-1.25x25,
each. The handles and screws are included in the Dual Robot Calibration Kit.

Required equipment:

• A pair of UR3, UR5 or UR10 robots, respectively, to be calibrated

• A stand with a height of at least 0.5 m for the Calibration Horse

• Dual Robot Calibration Kit from Universal Robots with purchase number: 185500, including:

– The UR Dual Robot Calibration Horse with alignment pins (Figure B.1, Appendix B)
– The UR Dual Robot Calibration Tool Connector with alignment pins (Figure B.2, Appendix B)
– Four M8-1.25x70 to mount the Calibration Horse to the stand (may differ depending on the robot
stand)
– Eight M8-1.25x25 screws with washers to mount UR5 and UR10 robots to the Calibration Horse
– Eight M6-1.0x25 screws with washers to mount the robot tools to the Calibration Tool Connector
– Eight M6-1.0x25 screws to mount UR3 robots to the Calibration Horse
– One Go tool used in the validating procedure, (Figure B.3, Appendix B)
– One No Go tool used in the validating procedure (Figure B.4, Appendix B)

Exception:

• The alignment pin for the tool connector, should not be used when calibrating UR5s produced prior to
end of 2014. This is due to the calibration requiring an improved version of the tool flange in UR5.

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 2. Dual Robot Calibration

2.2 Mounting the Robots to the Calibration Horse

(1) Mount the Calibration Horse to a stand of a height of at least 0.5 m and mount the robots to the Calibration
Horse, as in Figure 2.3.

(2) Mount two robots of the same type and version on the Calibration Horse, see Figure 2.3.

Figure 2.3: Mount the robots on the Calibration Horse, connecting the robot bases

(3) Set the robot mounting and angle, see Figure 2.4:

UR3:

(a) The Tilt is approximately 52, 5◦ ± 5◦ and

(b) The Rotate Robot Base Mounting is 270◦ .

UR5 and UR10:

(a) The Tilt is approximately 52, 5◦ ± 5◦ and

(b) The Rotate Robot Base Mounting is 90◦ .

(4) Set the payload to 0 kg for both robot types, see Figure 2.5.

4
3

Figure 2.4: Mounting of the robot Figure 2.5: TCP settings

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2. Dual Robot Calibration

2.3 Accessing the Functionality

The starting point for the method to select Kinematics Calibration in Expert Mode, see Figure 2.6. Secondly
select Dual Robot Calibration, see Figure 2.7.

Figure 2.6: Select Kinematics Calibration in Expert Figure 2.7: Select Dual Robot Calibration to select the
Mode. method.

2.4 Network Connection Between the Robots

The Dual Robot Calibration screen appears as shown in Figure 2.8. There are a number of options to choose
from within connection types which are described below:

• Master - the robot acts as master of the calibration process. Make sure that the other robot is selected as
Slave and that the two robots are connected with a network cable or switch.

• Slave - the robot acts as a slave in the calibration process. Make sure that the other robot is selected as
Master and that the two robots are connected with a network cable or switch.

• Manual - the robot acts as a master, but the slave robot is selected by an user supplied IP-address (see
description below).

The different connection types Master/Slave or Manual are described below.

(5) Connect the robot controllers with a network cable or through a network switch.

(6) Use ether the master/slave or manual connection method to establishment network connection between
the two robots controllers.

Note: Robot 1 is the master robot and Robot 2 is the slave.

Figure 2.8: Network options in Dual Robot Calibration.

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 2. Dual Robot Calibration

2.4.1 Master/Slave Connection

A Master/Slave connection works by connecting two robots via a network cable or over a network switch. One
robot have to be selected as master and the other as slave. Selecting one of these cases sets up the IP address
automatically.

CAUTION:
Notice that the IP-addresses 10.17.17.17.18 and 10.17.17.17.19 will be used for mas-
ter/slave connections. Connecting the robots to a local area network may interfere with other
devices having the same IP.

(7) When the slave (Robot 2) is ready and have entered the screen in Figure 2.9, press Connect network on
the master to establish the network connection, see Figure 2.10. The screens that follow are described in
Section 2.6.

Figure 2.9: Slave mode Figure 2.10: Master mode

2.4.2 Manual mode

Selecting Manual leads to the screen in Figure 2.11.

8
9

Figure 2.11: Manual enter IP address Figure 2.12: Set host name or IP address of the slave

(8) In Figure 2.11, Enter the IP number or host name of the Slave by clicking the text field with the text "IP
address or host name", see Figure 2.12.

(9) Connect by press Connect network, see Figure 2.11.

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2. Dual Robot Calibration

2.5 Before starting

The steps through the calibration are by default done automatically, unless it needs help from an operator. This
can be disabled by the Auto step checkbox, see Figure 2.13.

Figure 2.13: Calibration options

Furthermore, It is optional to save and correct the home position of each robot, which can be relevant if
only one of the robots need to be calibrated. However it is by default enabled.

Save calibration - means that the calculated kinematic calibration is applied and saved on the robot

Correct home position - means that it estimates and sets the home position using the calibration (define
new joint offset angles).

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 2. Dual Robot Calibration

2.6 Mounting the UR Dual Robot Calibration Connector

The robots are now ready to be physically connected if the robots are in their home position, see Figure 2.14.

(10) Ensure that the robots are in the Home position.

(11) Continue the procedure by pressing Connect Robots, see 2.15. If the robots are not in home position, a
pop-up will ask to move the robot to home (see Figure 2.16), before trying again.

Afterwards the robots will move into position as shown in Figure 2.17, ready to be connected.

11

Figure 2.14: Robots moved to the home position Figure 2.15: Press Connect robots to begin connection
the robots together, physically

Figure 2.16: Message telling that step no.: 10 was not Figure 2.17: Robots ready to be connected
performed. Press OK and move the robot to Home

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2. Dual Robot Calibration

(12) Attach the tool connector to the master robot (Robot 1) as in Figure 2.18.

(13) When the tool is mounted on the master robot (Robot 1), Press Proceed in the pop-up Figure 2.19.

(14) The slave robot (Robot 2) now enters free drive mode. Move the slave towards the connector and attach
the screws with washers. When done it looks like the fully connected robots shown in Figure 2.20.

(15) When the slave robot (Robot 2) is also mounted on the tool, Press Proceed in the pop-up Figure 2.21. This
step also starts the robot measuring each other by moving around.

13

12

Figure 2.18: Device connected to the master robot Figure 2.19: Proceed when the tool is mounted on
the master robot (Robot 1)

14

15

Figure 2.20: Robots fully connected Figure 2.21: Proceed when the robots are connected

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 2. Dual Robot Calibration

2.7 Measuring Positions and Calibration Statistics

After step no.: 15, the robot will begin measure and identify the calibration. First a number of initial measure-
ments are collected. A preliminary calibration is calculated from those. Second, the final set of measurements
will be done and the final calibration will be calculated, see Figure 2.22 and 2.23.

Figure 2.22: Collecting measurements Figure 2.23: Calculating the calibration

Afterwards, A statistics is given which describes whether the found calibration is usable (shown in green, see
Figure 2.24) or problematic (shown with red, see Figure 2.25).
If the result was successful as expected and the Auto step box is checked, it will automatically continue to step
no: 16.
Otherwise, The calibration results will be shown in red and the calibration procedure will not be able to continue,
see Figure 2.25. Please check how the robots are mounted with the Calibration Horse and the Calibration Tool
Connector and try again by redoing all the steps from no: 1.

Figure 2.24: Successful calibration Figure 2.25: Problematic calibration

The section Calibration Results contains the statistics for the accuracy of the found calibration. The Control
Results are statistics for a number of control measurements done throughout the calibration process which only
are used to validate the calibration.
The statistics are given in two units a) millimeters (mm) and milliradians (mrad) which refers to the RMS
deviation in Cartesian space. The statistics contains the fields:

Mean deviation: The average deviation in millimeters and in milliradians between the positions measured
by the first and second robot

Standard deviation: The standard deviation calculated on basis of the above

Max deviation: The maximal measured deviation

17
2. Dual Robot Calibration

Expected results

The calibration is passed successfully if:

• Mean deviation will be less than 1 mm and 2 mrad

• Standard deviation is less than 0.5 mm and 1 mrad

• The different between the Calibration and Control results is not more than 50% different

2.8 Applying the Calibration

After step no: 15 the calibration is applied to the controller and saved to be used in the future. The robots are
now ready to be disconnected.

(16) A pop-up appears as shown in Figure 2.26. Dismount the screws from the connector and press Proceed. If
the Auto step box is checked, the robots will continue with correcting the robots’ home position.

16

Figure 2.26: Remove screws

18
 2. Dual Robot Calibration

2.8.1 Validation
Next follows a validation procedure. Here both robot tool flanges need to be completely free from e.g. screws
and alignment pins.

(17) Remove the Calibration Tool Connector and alignment pins etc. and Proceed with the validation, see
Figure 2.28. The robots TCP will now approach one another.

(18) Verify that the distance in-between the robot tools is within a distance of 2.5 mm ±0.5 mm using the Go
and No Go tools, see Figure 2.29.

(a) Verify that the 2 mm Go tool can pass in-between the two robot’s tool flanges
(Figure B.3, Appendix B)
(b) Verify that the 3 mm No Go tool can not pass in-beween the two robot’s tool flanges
(Figure B.4, Appendix B)

(19) If the verification is successful in step no. 18, Proceed to the next validation step, see Figure 2.30.

17

Figure 2.27: Robots ready for the validation procee- Figure 2.28: Proceed to the Verification procedure
dure when the Calibration Tool Connector, screws, and
alignment pins are removed from the robots tool
flange

2.5 m m ± 0.5 m m

18 19

Figure 2.29: Verification by alignment of tools Figure 2.30: Proceed if the verification in step no. 18
is successful

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2. Dual Robot Calibration

Secondly the robots will move to their new calibrated home position. Here it is important that the robots are
fully stretch out and that the tools are pointing in the right direction, like in Figure 2.31. After completion of step
no. 21 the Dual Robot Calibration procedure has been completed, see Figure 2.33

(20) Verity the robot home positions, see 2.31.

(21) If the verification is successful in step no. 20, Proceed to the next validation step, see Figure 2.32.

(22) Calibration done, press Exit, see Figure 2.33.

20

21

Figure 2.31: Verify the robots new home position Figure 2.32: Proceed if the verification in step no. 20
succeed

22

Figure 2.33: Kinematic Calibration is done

2.8.2 Reset Calibration

The calibration can manually be adjusted or reset by editing the /root/.urcontrol/calibration.conf file placed
together with the other configurations. To reset the calibration all decimal and hex numbers is reset to zero like
in Listing 1.2 in page 8.

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 A. Calibration Plate

A Calibration Plate

785mm M10

775mm M10

M8
Plate dimension:
800x800x12[mm]
(630,630) (630,504) (630,378) (630,252) (630,126) (630,0)

Drawing
63mm
31.002.05
Ø63 [H7]
(567,567) (567,441) (567,315) (567,189) (567,63)
M8 M8
63mm

(504,630) (504,504) (504,378) (504,252) (504,126) (504,0)

640mm

63mm Ø8 [H7]

(441,567) (441,441) (441,315) (441,189) (441,63)

63mm

(378,630) (378,504) (378,378) (378,252) (378,126) (378,0)

450mm
M10
63mm
500mm
(315,567) (315,441) (315,315) (315,189) (315,63)

63mm

(252,630) (252,504) (252,378) (252,252) (252,126) (252,0)

63mm

(189,567) (189,441) (189,315) (189,189) (189,63)

300mm
63mm

(126,630) (126,504) (126,378) (126,252) (126,126) (126,0)

63mm
x

(63,567) (63,441) (63,315) (63,189)

Stift
63mm Drawing
31.320.08
160mm
(0,630) (0,504) (0,378) (0,252) (0,126) (0,0)
y M8

85mm Stift
M8

Ø132
M10
25mm 15mm M10

85 mm 785mm
63 mm 63 mm 63 mm 63 mm 63 mm 63 mm 63 mm 63 mm 63 mm 63 mm
15mm
415 mm
640mm 775mm
300mm 500mm
160mm
25mm

Figure A.1: Drawing of the calibration plate.

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B. Dual Robot Tools

B Dual Robot Tools

UR10

UR5

UR3
Cable

UR10
Cable
UR3

UR5
Figure B.1: A sketch of the Dual Robot Calibration Horse

Figure B.2: A sketch of the Dual Robot Calibration Tool Connector

Figure B.3: Go tool used in the validating procedure (2 mm thickness)

Figure B.4: No Go tool used in the validating procedure (3 mm thickness)

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 C. Robot DH Parameter

C Robot DH Parameter
The robots kinematic transformations for each link are given by Denavite-Hartenberg(DH) parameters.

C.1 UR3

θ [r a d ] a [m ] d [m ] α [r a d ]
π
Joint 1: 0 0 0.118 2
Joint 2: 0 −0.2437 0 0
Joint 3: 0 −0.2133 0 0
π
Joint 4: 0 0 0.1124 2
−π
Joint 5: 0 0 0.0854 2
Joint 6: 0 0 0.0819 0

Table C.1: Denavit-Hartenberg parameters for the UR3 robot

C.2 UR5

θ [r a d ] a [m ] d [m ] α [r a d ] θ [r a d ] a [m ] d [m ] α [r a d ]
π π
Joint 1: 0 0 0.08920 2
Joint 1: 0 0 0.08920 2
Joint 2: 0 −0.42500 0 0 Joint 2: 0 −0.42500 0 0
Joint 3: 0 −0.39243 0 0 Joint 3: 0 −0.39225 0 0
π π
Joint 4: 0 0 0.10900 2
Joint 4: 0 0 0.11000 2
−π −π
Joint 5: 0 0 0.09300 2
Joint 5: 0 0 0.09475 2
Joint 6: 0 0 0.08200 0 Joint 6: 0 0 0.08250 0

Table C.2: Denavit-Hartenberg parameters for the Table C.3: Denavit-Hartenberg parameters for the
UR5 serie 1 UR5 serie 2

θ [r a d ] a [m ] d [m ] α [r a d ]
π
Joint 1: 0 0 0.089159 2
Joint 2: 0 −0.42500 0 0
Joint 3: 0 −0.39225 0 0
π
Joint 4: 0 0 0.10915 2
−π
Joint 5: 0 0 0.09465 2
Joint 6: 0 0 0.08230 0

Table C.4: Denavit-Hartenberg parameters for the UR5 serie 3.

C.3 UR10

θ [r a d ] a [m ] d [m ] α [r a d ]
π
Joint 1: 0 0 0.118 2
Joint 2: 0 −0.6127 0 0
Joint 3: 0 −0.5716 0 0
π
Joint 4: 0 0 0.1639 2
−π
Joint 5: 0 0 0.1157 2
Joint 6: 0 0 0.0922 0

Table C.5: Denavit-Hartenberg parameters for the UR10 robot

23