Anytime a robot manipulator is controlled via visual feedback, the transformation between the robot and camera frame must be known. However, in the case where cameras can only capture a portion of the robot manipulator in order to better perceive the environment being interacted with, there is greater sensitivity to errors in calibration of the base-to-camera transform. A secondary source of uncertainty during robotic control are inaccuracies in joint angle measurements which can be caused by biases in positioning and complex transmission effects such as backlash and cable stretch. In this work, we bring together these two sets of unknown parameters into a unified problem formulation when the kinematic chain is partially visible in the camera view. We prove that these parameters are non-identifiable implying that explicit estimation of them is infeasible. To overcome this, we derive a smaller set of parameters we call Lumped Error since it lumps together the errors of calibration and joint angle measurements. A particle filter method is presented and tested in simulation and on two real world robots to estimate the Lumped Error and show the efficiency of this parameter reduction.
Markerless Camera-to-Robot Pose Estimation via Self-Supervised Sim-to-Real Transfer
Solving the camera-to-robot pose is a fundamental requirement for vision-based robot control, and is a process that takes considerable effort and cares to make accurate. Traditional approaches require modification of the robot via markers, and subsequent deep learning approaches enabled markerless feature extraction. Mainstream deep learning methods only use synthetic data and rely on Domain Randomization to fill the sim-to-real gap, because acquiring the 3D annotation is labor-intensive. In this work, we go beyond the limitation of 3D annotations for real-world data. We propose an end-to-end pose estimation framework that is capable of online camera-to-robot calibration and a self-supervised training method to scale the training to unlabeled real-world data. Our framework combines deep learning and geometric vision for solving the robot pose, and the pipeline is fully differentiable. To train the Camera-to-Robot Pose Estimation Network (CtRNet), we leverage foreground segmentation and differentiable rendering for image-level self-supervision. The pose prediction is visualized through a renderer and the image loss with the input image is back-propagated to train the neural network. Our experimental results on two public real datasets confirm the effectiveness of our approach over existing works. We also integrate our framework into a visual servoing system to demonstrate the promise of real-time precise robot pose estimation for automation tasks.
Pose Estimation for Robot Manipulators via Keypoint Optimization and Sim-to-Real Transfer
Keypoint detection is an essential building block for many robotic applications like motion capture and pose estimation. Historically, keypoints are detected using uniquely engineered markers such as checkerboards or fiducials. More recently, deep learning methods have been explored as they have the ability to detect user-defined keypoints in a marker-less manner. However, different manually selected keypoints can have uneven performance when it comes to detection and localization. An example of this can be found on symmetric robotic tools where DNN detectors cannot solve the correspondence problem correctly. In this work, we propose a new and autonomous way to define the keypoint locations that overcomes these challenges. The approach involves finding the optimal set of keypoints on robotic manipulators for robust visual detection and localization. Using a robotic simulator as a medium, our algorithm utilizes synthetic data for DNN training, and the proposed algorithm is used to optimize the selection of keypoints through an iterative approach. The results show that when using the optimized keypoints, the detection performance of the DNNs improved significantly. We further use the optimized keypoints for real robotic applications by using domain randomization to bridge the reality gap between the simulator and the physical world. The physical world experiments show how the proposed method can be applied to the wide-breadth of robotic applications that require visual feedback, such as camera-to-robot calibration, robotic tool tracking, and end-effector pose estimation.