System and method for robust calibration between a machine vision system and a robot

1. A method for determining calibration between a machine vision system and a robot, the method comprising:

obtaining, using a camera fixed to an effector of the robot, an initial image of a calibration object fixed in space as the robot occupies an initial pose within a workplace for the robot, and a subsequent image of the calibration object as the robot occupies a subsequent post within the workplace for the robot, the initial pose and the subsequent pose are different, the calibration object comprising a first object feature and a second object feature, the first object feature and the second object feature located at a fixed, known distance relative to one another, the robot having a robot coordinate system, the camera having a camera coordinate system, the effector having an effector coordinate system, the calibration object having an object coordinate system;

identifying an object-robot transform between the object coordinate system and the robot coordinate system;

identifying a camera-effector transform between the object coordinate system and the effector coordinate system;

locating a first initial image feature and a second initial image feature in the initial image and a first subsequent image feature and a second subsequent image feature in the subsequent image, the first initial image feature and the first subsequent image feature corresponding to the first object feature and the second initial image feature and the second subsequent image feature corresponding to the second object feature;

calculating, using the fixed, known distance, the initial pose, the subsequent pose, the object-robot transform, and the camera-effector transform, a predicted first initial image feature and a predicted second initial image feature for the initial image and a predicted first subsequent image feature and a predicted second subsequent image feature for the subsequent image, the predicted first initial image feature and the predicted first subsequent image feature corresponding to the first object feature and the predicted second initial image feature and the predicted second subsequent image feature corresponding to the second object feature;

minimizing, by varying the object-robot transform or the camera-effector transform, a discrepancy between at least one of the first initial image feature and the predicted first initial image feature, the second initial image feature and the predicted second initial image feature, the first subsequent image feature and the predicted first subsequent image feature, and the second subsequent image feature and the predicted second subsequent image feature, thereby producing optimized transforms;

calibrating the machine vision system and the robot using the optimized transforms.

2. The method of claim 1 wherein the calibration object comprises a calibration plate.

3. The method of claim 1 wherein a difference between the initial pose and the subsequent pose comprises rotations around at least two non-parallel axes.

4. The method of claim 3 wherein the rotations comprise rotation of at least five degrees.

5. The method of claim 1 further comprising pre-processing a set of obtained images to remove outliers, where the pre-processing further comprises:

determining a set of outliers;

eliminating, in response to determining a set of outliers, one or more images from the set of obtained images having the outliers to produce a reduced set of obtained images; and

re-ordering the reduced set of obtained images to obtain suitable motions.

6. The method of claim 5 wherein the suitable motions comprises changes between a particular pair of the reduced set of obtained images.

7. The method of claim 1 wherein the transforms permit six degrees of freedom.