Mikhail Malyshev

This study introduces an approach for open-loop geometric calibration of industrial manipulators that integrates three widely used kinematic formulations: Denavit – Hartenberg (DH), Product of Exponentials (POE), and Complete Parametric Continuous (CPC) models. The proposed method focuses on identifying optimal measurement configurations within a local, spatially narrow workspace, which is a common operational scenario in industrial robotic applications. To achieve high calibration efficiency, a linear approximation model was employed, and the measurement configurations were selected using the D-optimality criterion to maximize parameter identifiability. Experimental validation was performed on an ABB IRB 1600 (10/1.45) manipulator equipped with an API Radian Laser Tracker EMSD3 measurement system, providing a linear accuracy of 0.7 $\mu$m per meter. The system was equipped with a Smart Track Sensor offering an orientation accuracy of 0.005 degrees. Independent measurement sets were used for experiments for each model in several variations to identify the best parameter estimates that can be used in the future for this robot. The results demonstrate a substantial enhancement in calibration accuracy. Specifically, applying the POE-based identification procedure within the narrow workspace region reduced the average error in the Tool Center Point (TCP) position by a factor of 22 when compared to the uncalibrated nominal parameters, with the mean error decreasing from 2.852 mm to 0.13 mm. Additionally, the repeatability analysis showed that the standard deviation of TCP position errors across repeated measurements did not exceed 0.007 mm. These results confirm that the proposed approach ensures high calibration precision and robustness suitable for high-accuracy industrial robotic tasks.