It is traditionally difficult to implement fast and accurate position regulation on an industrial robot in the presence of uncertainties. The uncertain factors can be attributed either to the industrial robot itself (e.g., a mismatch of dynamics, mechanical defects such as backlash, etc.) or to the external environment (e.g., calibration errors, misalignment or perturbations of a workpiece, etc.). This paper proposes a systematic approach to implement high-performance position regulation under uncertainties on a general industrial robot (referred to as the main robot) with minimal or no manual teaching. The method is based on a coarse-to-fine strategy that involves configuring an add-on module for the main robot’s end effector. The add-on module consists of a 1000 Hz vision sensor and a high-speed actuator to compensate for accumulated uncertainties. The main robot only focuses on fast and coarse motion, with its trajectories automatically planned by image information from a static low-cost camera. Fast and accurate peg-and-hole alignment in one dimension was implemented as an application scenario by using a commercial parallel-link robot and an add-on compensation module with one degree of freedom (DoF). Experimental results yielded an almost 100% success rate for fast peg-in-hole manipulation (with regulation accuracy at about 0.1 mm) when the workpiece was randomly placed.
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