Calibration strategies for enhancing accuracy in serial industrial robots for orbital milling applications

PurposeThis research paper aims to optimize the calibration process for an ABB IRB 120 robot, specifically for robotic orbital milling applications, by introducing and validating the use of the observability index and telescopic ballbar for accuracy enhancement.Design/methodology/approachThe study uses the telescopic ballbar and an observability index for the calibration of an ABB IRB 120 robot, focusing on robotic orbital milling. Comparative simulation analysis selects the O3 index. Experimental tests, both static and dynamic, evaluate the proposed calibration approach within the robot's workspace.FindingsThe proposed calibration approach significantly reduces circularity errors, particularly in robotic orbital milling, showcasing effectiveness in both static and dynamic modes at various tool center point speeds.Research limitations/implicationsThe study focuses on a specific robot model and application (robotic orbital milling), limiting generalizability. Further research could explore diverse robot models and applications.Practical implicationsThe findings offer practical benefits by enhancing the accuracy of robotic systems, particularly in precision tasks like orbital milling, providing a valuable calibration method.Social implicationsWhile primarily technological, improved robotic precision can have social implications, potentially influencing fields where robotic applications are crucial, such as manufacturing and automation.Originality/valueThis study's distinctiveness lies in advancing the accuracy and precision of industrial robots during circular motions, specifically tailored for orbital milling applications. The innovative approach synergistically uses the observability index and telescopic ballbar to achieve these objectives.