Calibration of robotic drilling systems with a moving rail

Industrial robots are widely used in aircraft assembly systems such as robotic drilling systems. It is necessary to expand a robot’s working range with a moving rail. A method for improving the position accuracy of an automated assembly system with an industrial robot mounted on a moving rail is proposed. A multi-station method is used to control the robot in this study. The robot only works at stations which are certain positions defined on the moving rail. The calibration of the robot system is composed by the calibration of the robot and the calibration of the stations. The calibration of the robot is based on error similarity and inverse distance weighted interpolation. The calibration of the stations is based on a magnetic strip and a magnetic sensor. Validation tests were performed in this study, which showed that the accuracy of the robot system gained significant improvement using the proposed method. The absolute position errors were reduced by about 85% to less than 0.3 mm compared with the maximum nearly 2 mm before calibration.