Precise Robotic Assembly for Large-Scale Objects Based on Automatic Guidance and Alignment

A precise robotic assembly for large-scale objects is an important application in manufacture. In this paper, we design a new assembly system for large-scale objects based on automatic guidance and alignment with two cameras and three laser distance sensors. The corresponding strategy consists of three stages. First, the object is guided from a remote position to a close one based on our proposed link-line model-based polygon detection and Computer Aided Design (CAD)-View method. Second, the object is aligned to the installation framework based on the proposed visual and laser alignment method. Finally, the object is automatically inserted into the installation framework. An accurate easily applying and close-loop hand-eye calibration method is also proposed. The proposed assembly system has high assembly precision and efficiency. In our test for a 710 mm × 625 mm optical module, the maximum 6-DOF localization error of guidance and alignment is 0.53 mm in translation and 0.10° in orientation. The mechanical constraint-based controlling accuracy, i.e., the final assembly accuracy, is up to 0.2 mm in translation.