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Changelog

All notable changes to this project will be documented in this file.

[Unreleased]

Changed

  • 🏗️ Major Project Restructure - Migrated to src/ layout for better packaging and development
    • Moved all source code to src/ur_toolkit/
    • Moved executable scripts to scripts/
    • Moved configuration files to config/
    • Moved documentation to docs/ (renamed from documentation/)
    • Moved workflow examples to examples/workflows/
    • Updated all import paths to use ur_toolkit. prefix
    • Created proper pyproject.toml for modern Python packaging
    • Updated README.md with new structure and corrected paths
  • Pi Camera Server - Kept as separate deployment component outside src/ structure

Added

  • Comprehensive Code Cleanup - Fixed all flake8 linting errors across the entire codebase (reduced from 336 to 0 errors)
  • File-by-File Code Cleanup - Systematically cleaned up individual files including ur_controller.py, config_manager.py, and entire visual_servo/ folder (config.py, detection_filter.py, pose_history.py, visual_servo_engine.py)
  • Import Path Stability - Added .env file for PYTHONPATH configuration and VS Code settings for consistent imports
  • Flake8 Configuration - Created .flake8 config file to ignore style-only errors while maintaining functional code quality
  • File Organization - Deleted all unnecessary debugging/test files and pycache directories
  • Duplicate File Removal - Removed obsolete ur_robot_interface.py duplicate of ur_controller.py
  • PID-Based Visual Servoing Stability - Implemented conservative PID controllers for eye-in-hand visual servoing with automatic gain reduction
  • Stability Testing Framework - Added test script to verify PID controller stability and error tracking behavior
  • Automatic Equipment Association - All position teaching now automatically prompts for equipment association and observation pose setup
  • Enhanced Position Teaching Workflow - Unified approach for both regular and freedrive position teaching with equipment linking
  • Improved Equipment Management - Automatic offset calculation between work positions and observation poses for visual servoing
  • Clean YAML Structure - Removed irrelevant fields (timestamps, freedrive flags) and AprilTag data from work positions
  • Dual-Purpose Positions - Work positions can also serve as observation poses when they have AprilTag view and no other observation pose exists
  • Smart AprilTag Data Management - Only observation poses store AprilTag data; work positions use observation poses for visual servoing
  • Intelligent Prompting - When AprilTag is detected during position teaching, defaults to dual-purpose position with negative confirmation prompt
  • Comprehensive File Organization - Moved CHANGELOG.md to documentation/, renamed config/ to setup/, moved requirements.txt and setup_venv.sh to setup/
  • Enhanced Directory Organization - Created positions/ directory for position files and moved teach_positions.py there
  • Project Structure Organization - Created workflow/ directory for workflow-related files and workflow/examples/ for YAML examples
  • Path Resolution Fix - Updated import paths in workflow files to work from subdirectory structure
  • URController Refactor - Renamed URRobotInterface to URController and file to ur_controller.py for cleaner, more intuitive naming
  • moveJ Action - Added joint move (moveJ) alongside linear move (moveL) for different movement types
  • Condensed Workflow YAML - Removed explicit step names, auto-generate descriptive names, replaced move_to_position with moveL
  • Step-by-Step Workflow Execution - Interactive mode with user prompts before each step and automatic delay skipping
  • Improved YAML Formatting - Inline arrays for coordinates/joints, rounded values, spacing between entries, removed usage tracking
  • Safe Position Reachability Testing - Automatic movement test after creating safe offset positions to verify accessibility
  • Enhanced Interactive Menu - Support for both number (1-8) and keyword inputs (teach, list, move, etc.)
  • Simplified Safe Offset System - Automatic prompting for safe positions after teaching with simple direction/distance input
  • Remote Freedrive Teaching - Simplified position teaching with blocking input (no timer/threading)
  • Streamlined Interactive Menu - Removed legacy manual teaching option, focused on remote freedrive workflow
  • Robot Workflow System - YAML-based workflow execution for sequential robot operations

Changed

  • Visual Servoing Stability - Reduced PID gains (kp: 2.0→0.5), removed integral/derivative terms, added conservative output limits
  • Visual Servo Configuration - Reduced max_iterations (5→3) and damping_factor (0.7→0.3) for enhanced stability
  • Error Tracking - Added automatic gain reduction when error increases to prevent oscillation and overshoot

Removed

  • Debugging Test Files - Deleted test_freedrive_focused.py, test_freedrive_remote.py, test_remote_freedrive_teacher.py
  • Legacy Actions - Removed home and move_to_position actions in favor of moveL/moveJ for cleaner, standardized API
  • URRobotInterface - Replaced with shorter, more intuitive URController class name

Removed

  • Usage Tracking - Removed usage_count and last_used fields for cleaner position files
  • Workflow Actions - Move to position, offset moves, gripper control, delays, position verification
  • Sample Workflows - Pick and place demo, inspection routines, and simple test workflows
  • Workflow Runner - Easy-to-use script for executing workflows with safety checks
  • Position Overwrite Confirmation - Safety prompts when reteaching existing positions to prevent accidental data loss
  • Rich Position Metadata Collection - Interactive prompts for position description, equipment, type, priority, and safety notes
  • Enhanced Position Teaching Workflow - Automatic prompting to teach observation poses when no AprilTags detected
  • Observation Pose Auto-Teaching - Streamlined workflow to teach observation poses immediately after grasp positions
  • Smart Position Linking - Automatic linking of positions to newly created observation poses
  • Equipment Association - Mandatory equipment linking for observation poses with validation
  • Manual Position Teaching - Position teaching using teach pendant freedrive with RTDE pose reading (no remote control commands)
  • Two-Pose Teaching System - Work poses and observation poses for positions with/without AprilTag visibility
  • Position Linking Commands - CLI and interactive commands to link positions to observation poses (link command)
  • Clean YAML Format - Human-readable position storage with essential data only (TCP pose, joint angles, AprilTag ID)
  • Read-Only Robot Interface - Safe RTDE connection that only reads poses, no movement commands
  • Interactive Teaching Mode - CLI interface for real-time position teaching and management
  • Robotiq Gripper Control - Socket-based gripper control via URCap port 63352 following RTDE documentation
  • Position teaching configuration in unified config.yaml
  • Position verification using AprilTag visibility detection
  • Position management (teach, observe, link, move, verify, list, delete)
  • Comprehensive position teaching documentation in documentation/POSITION_TEACHING.md
  • Enhanced position teaching workflow documentation in documentation/ENHANCED_POSITION_TEACHING.md
  • Unified configuration system with central config.yaml file in project root
  • config_manager.py module for centralized configuration access
  • Configuration guide in documentation/CONFIGURATION_GUIDE.md
  • Support for environment-based configuration overrides
  • Path resolution utilities for robust file path handling
  • Convenience functions for common configuration access patterns

Fixed

  • Fixed AprilTag detector initialization error with undefined tag family variable
  • Fixed robot interface disconnect method call (should be close() not disconnect())
  • Improved error handling and validation in AprilTag detector initialization
  • Added better diagnostics for AprilTag detector failures
  • Fixed camera calibration file loading in AprilTag detector
  • Resolved import errors for camera module (picam) in CLI and detection modules
  • Updated camera/picam/__init__.py to properly expose PiCam and PiCamConfig classes
  • Fixed import paths in apriltag_detection.py and teach_positions.py to use proper Python package structure
  • Corrected sys.path management for cross-module imports

Changed

  • Updated robots/ur/ur_robot_interface.py to use centralized configuration
  • Updated apriltag_detection.py to use centralized configuration
  • All modules now import from config_manager instead of individual config files
  • Configuration values now support dot notation access (e.g., robot.ip_address)
  • Command-line arguments now override config file values consistently

Improved

  • Simplified configuration management - single source of truth
  • Better path handling - no more broken references when moving files
  • Consistent configuration access patterns across all modules
  • Built-in defaults and graceful fallbacks
  • Configuration validation and debugging capabilities

Removed

  • handeye_calibration/ directory and all hand-eye calibration scripts: collect_handeye_data.py, calculate_handeye_calibration.py, coordinate_transformer.py, etc.
  • handeye_rework/ directory and experimental calibration approaches
  • Hand-eye calibration related files from root: handeye_result.yaml, handeye_samples.json, analyze_motion.py, check_distances.py, test_close_distance.py
  • Hand-eye calibration sections from README.md, simplified to focus on pure AprilTag detection workflow
  • Individual config files (camera_client_config.yaml, robots/ur/robot_config.yaml) - now consolidated

Rationale

  • Hand-eye calibration was not producing realistic results
  • AprilTag detection works effectively without requiring camera-to-robot transformation
  • Simplified codebase focuses on core functionality: camera capture, AprilTag detection, and robot control as separate components
  • handeye_rework/collect_samples.py: implemented real robot/camera/apriltag hooks using existing interfaces
  • Configuration consolidation eliminates path issues and simplifies system management

[2025-09-12] - Camera Coordinate Frame Correction for Hand-Eye Calibration

Added

  • tests/test_camera_coordinate_frame.py - Empirical camera frame mapping test with automatic robot movement
  • Coordinate frame correction in calculate_handeye_calibration.py
  • Camera-to-robot coordinate transformation matrix based on empirical testing

Changed

  • Updated hand-eye calibration to account for OpenCV camera frame vs robot frame differences
  • Robot X+ (RIGHT) → Camera X+, Robot Y+ (BACK) → Camera Z+, Robot Z+ (UP) → Camera Y+
  • Applied coordinate transformation: Camera [X,Y,Z] → Robot [X,Z,-Y]

Fixed

  • Hand-eye calibration offset issue (~0.95m → expected 10-30cm) by correcting coordinate frame mismatch
  • Camera pose data now properly transformed from OpenCV convention to robot frame before calibration

[2025-09-11] - Code Organization and Testing Utilities

Added

  • tests/live_robot_monitor.py - Real-time robot pose monitoring with quaternion/matrix display
  • tests/rotations_cli.py - CLI utility for rotation vector analysis and comparison
  • tests/debug_coordinate_frames.py - Coordinate frame debugging utility

Changed

  • Moved debugging and testing utilities from main directory to tests/
  • Improved code organization by separating core functionality from testing tools

[2025-01-20] - TCP Pose Accuracy and Configuration Management

Added

  • Centralized robot configuration via robots/ur/robot_config.yaml
  • TCP pose sign verification utility (robots/ur/test_pose_signs.py)
  • Command-line IP override support for all robot scripts
  • Configuration loading with fallback to defaults

Fixed

  • Removed incorrect Ry/Rz sign corrections - raw RTDE readings now match teach pendant
  • Eliminated hardcoded robot IPs throughout codebase
  • TCP pose reading accuracy for reliable hand-eye calibration

Changed

  • ur_robot_interface.py: Now loads robot IP and settings from YAML config
  • test_robot_pose.py: Added config file support with command-line override
  • collect_handeye_data.py: Added config file support with command-line override
  • All robot scripts now use centralized configuration management

Previous

Added

  • Comprehensive AprilTag pick-and-place workflow documentation in README
  • TCP pose reading accuracy verification utility (robots/ur/test_robot_pose.py)
  • Read-only mode for safer hand-eye calibration data collection
  • Improved calibration file path handling to save in proper directories

Fixed

  • Hand-eye calibration TCP pose reading accuracy issues
  • Calibration data file paths now save to correct handeye_calibration directory

Changed

  • Hand-eye calibration data collection now uses read-only mode by default
  • Updated workflow documentation with immediate testing after each setup step

[2025-09-05] - Hand-Eye Calibration Improvements

Summary

  • Addressed TCP pose reading accuracy that was affecting hand-eye calibration quality
  • Improved safety and workflow for calibration data collection
  • Added comprehensive documentation for complete AprilTag workflow

Next Steps

  • Verify TCP pose accuracy using the new test utility
  • Re-collect hand-eye calibration data with corrected pose readings
  • Continue refinement of calibration quality metrics