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<p>In advanced manufacturing fields such as aerospace, achieving high-precision cooperative positioning for dual-robot systems remains a critical challenge. Conventional calibration methods usually treat geometric error sources separately and calibrate them step by step, which can cause residual errors from one stage to propagate into the next and makes it difficult to compensate coupled system errors. This paper proposes a unified calibration framework to address this limitation. The master robot, the slave robot, and the base-to-base relationship are modeled as a single continuous kinematic chain. Based on this unified model, a cooperative error Jacobian matrix is derived for 78 geometric error parameters, and the Levenberg–Marquardt algorithm is used for parameter identification. Experimental results show that the mean absolute positioning errors in the <i>x</i>, <i>y</i>, and <i>z</i> directions decreased from 1.386&#xa0;mm, 1.361&#xa0;mm, and 0.341&#xa0;mm to 0.391&#xa0;mm, 0.387&#xa0;mm, and 0.245&#xa0;mm, corresponding to reductions of 71.8%, 71.6%, and 28.2%, respectively. After calibration, the cooperative positioning error of the dual-robot system remained below 0.8&#xa0;mm. These results indicate that the proposed method can support dual-robot machining and assembly tasks that require sub-millimeter cooperative positioning.</p>

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Unified geometric error modeling and cooperative calibration method for high precision dual-robot machining systems

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Zhen Fan,
  • Bo Li,
  • Wei Tian

摘要

In advanced manufacturing fields such as aerospace, achieving high-precision cooperative positioning for dual-robot systems remains a critical challenge. Conventional calibration methods usually treat geometric error sources separately and calibrate them step by step, which can cause residual errors from one stage to propagate into the next and makes it difficult to compensate coupled system errors. This paper proposes a unified calibration framework to address this limitation. The master robot, the slave robot, and the base-to-base relationship are modeled as a single continuous kinematic chain. Based on this unified model, a cooperative error Jacobian matrix is derived for 78 geometric error parameters, and the Levenberg–Marquardt algorithm is used for parameter identification. Experimental results show that the mean absolute positioning errors in the x, y, and z directions decreased from 1.386 mm, 1.361 mm, and 0.341 mm to 0.391 mm, 0.387 mm, and 0.245 mm, corresponding to reductions of 71.8%, 71.6%, and 28.2%, respectively. After calibration, the cooperative positioning error of the dual-robot system remained below 0.8 mm. These results indicate that the proposed method can support dual-robot machining and assembly tasks that require sub-millimeter cooperative positioning.