Methods for locating and sensing the position, orientation, and contour of a work object in a robotic system

Abstract

Methods and apparatus enable a robotic system to detect and determine the location, orientation, surface contours, and features of an object that are not otherwise accurately known in order to allow the robotic system to accurately place a pulse/echo layer thickness-gauge ultrasonic transducer gauge onto the surface of the object. The robotic system uses one or more distance measurement sensors to determine the position, orientation, local contour, and other features of the surface in relation to the robot. Another method calibrates an inaccurate distance sensor. Yet another method maintains overall system functionality in a system with multiple distance sensors in the event that one or more of the distance sensors fails. The robotic system may also determine when maintenance is required.