A Stylus-Based Calibration Method for Robotic Belt Grinding Tools

To address the tool calibration challenge in robotic systems equipped with grinding tools, this paper proposes a high-precision method utilizing a stylus assembly and the Particle Swarm Optimization (PSO) algorithm. A global optimization strategy is implemented, which simultaneously identifies and compensates for coupled error sources, including the robot’s kinematic (DH) parameters, the tool coordinate frame (TCF), and the stylus tip’s spatial position. This approach transforms the complex calibration task into a constrained, high-dimensional optimization problem. The experimental results demonstrate the method’s effectiveness, reducing the final calibration Root Mean Square Error (RMSE) to below 0.1 mm. Validation through a practical grinding experiment confirmed a significant improvement in machining accuracy, with the workpiece’s axis deviation from the ideal model decreasing from 1.477° to 0.326°, and the maximum contour error being reduced from 1.4 mm to under 0.3 mm. This study provides a robust, low-cost technical solution for tool calibration in complex industrial applications.