For off-line programming to work, systematic methods must be developed to account for non-ideal performance of the parts and devices in the manufacturing cell. Although much of the literature focuses on robot inaccuracy, this paper considers practical methods for the tool control frame (TCF) calibration and rigid-body compensation required to close the inverse kinematics loop for target driven tasks.

In contrast to contemporary estimation methods, a closed-form, easily automated, solution is introduced for calibrating the position and orientation (pose) of orthogonal end-effectors when the distal robot joint is revolute. This paper also considers methods for measuring and compensating the small rigid-body perturbations that result from non-repeatable part delivery systems or from geometric distortion. These methods are designed to eliminate rθ error from the rigid-body prediction and can be conducted in real-time. Without accurate TCF calibration and rigid-body compensation, even the most accurate robot will fail to complete an off-line programmed task if the task tolerances are stringent.