Assessing path accuracy in industrial robots via ballbar technology

Purpose This paper aims to present a methodology for evaluating the path accuracy of industrial robots using the telescoping ballbar measurement technology. The goal is to improve accuracy assessments in precision-driven manufacturing processes. Design/methodology/approach A single telescoping ballbar is used to assess the circle contouring performance of a KUKA KR210 R2700 prime robot. Experiments involve system setup, data collection and analysis in Matlab to derive performance metrics such as radial deviation, circularity and path accuracy error. This study investigates the impact of varying the operational conditions, including speed, payload and robot configuration, on these indexes through statistical analysis, and examines the relationship between joint errors and path deviations. Findings The results indicate that the robot behavior is influenced by the operating conditions, with notable error spikes at joint reversal positions due to factors such as joint backlash and transmission errors. This study evaluates various performance indexes from different standards, ISO 230 and ISO 9283, and identifies key operating parameters influencing each index. The findings suggest effective strategies for error compensation and performance enhancement. Originality/value This paper offers a novel approach to path accuracy verification and error source identification in industrial robots. It proposes methods to rapidly assess the correlation between performance and operating conditions, offering insights for better calibration and control strategies, especially in high-precision tasks.