Geometric Parameter Calibration for a Cable-Driven Parallel Robot Based on a Single One-Dimensional Laser Distance Sensor Measurement and Experimental Modeling

A cable-driven parallel robot has benefits of wide workspace, high payload, and high dynamic response owing to its light cable actuator utilization. For wide workspace applications, in particular, the body frame becomes large to cover the wide workspace that causes robot kinematic errors resulting from geometric uncertainty. However, appropriate sensors as well as inexpensive and easy calibration methods to measure the actual robot kinematic parameters are not currently available. Hence, we present a calibration sensor device and an auto-calibration methodology for the over-constrained cable-driven parallel robots using one-dimension laser distance sensors attached to the robot end-effector, to overcome the robot geometric uncertainty and to implement precise robot control. A novel calibration workflow with five phases—preparation, modeling, measuring, identification, and adjustment—is proposed. The proposed calibration algorithms cover the cable-driven parallel robot kinematics, as well as uncertainty modeling such as cable elongation and pulley kinematics. We performed extensive simulations and experiments to verify the performance of the suggested method using the MINI cable robot. The experimental results show that the kinematic parameters can be identified correctly with 0.92 mm accuracy, and the robot position control accuracy is increased by 58%. Finally, we verified that the developed calibration sensor devices and the calibration methodology are applicable to the massive-size cable-driven parallel robot system.