A new one-time registration method was developed in this research for hand-eye calibration of a surgical robot to simplify the operation process and reduce the preparation time. And a new and practical method is introduced in this research to optimize the end-tool parameters of the surgical robot based on analysis of the error sources in this registration method. In the process with one-time registration method, firstly a marker on the end-tool of the robot was recognized by a fixed binocular camera, and then the orientation and position of the marker were calculated based on the joint parameters of the robot. Secondly the relationship between the camera coordinate system and the robot base coordinate system could be established to complete the hand-eye calibration. Because of manufacturing and assembly errors of robot end-tool, an error equation was established with the transformation matrix between the robot end coordinate system and the robot end-tool coordinate system as the variable. Numerical optimization was employed to optimize end-tool parameters of the robot. The experimental results showed that the one-time registration method could significantly improve the efficiency of the robot hand-eye calibration compared with the existing methods. The parameter optimization method could significantly improve the absolute positioning accuracy of the one-time registration method. The absolute positioning accuracy of the one-time registration method can meet the requirements of the clinical surgery.
In order to calibrate the hand-eye transformation of the surgical robot and laser range finder (LRF), a calibration algorithm based on a planar template was designed. A mathematical model of the planar template had been given and the approach to address the equations had been derived. Aiming at the problems of the measurement error in a practical system, we proposed a new algorithm for selecting coplanar data. This algorithm can effectively eliminate considerable measurement error data to improve the calibration accuracy. Furthermore, three orthogonal planes were used to improve the calibration accuracy, in which a nonlinear optimization for hand-eye calibration was used. With the purpose of verifying the calibration precision, we used the LRF to measure some fixed points in different directions and a cuboid’s surfaces. Experimental results indicated that the precision of a single planar template method was (1.37±0.24) mm, and that of the three orthogonal planes method was (0.37±0.05) mm. Moreover, the mean FRE of three-dimensional (3D) points was 0.24 mm and mean TRE was 0.26 mm. The maximum angle measurement error was 0.4 degree. Experimental results show that the method presented in this paper is effective with high accuracy and can meet the requirements of surgical robot precise location.