On-Site Implementation of External Wrench Measurement via Non-Linear Optimization in Six-Axis Force–Torque Sensor Calibration and Crosstalk Compensation

This study introduces a novel calibration method for accurate external wrench measurement using a six-axis FT (force–torque) sensor. We propose a sensor model and calibration method for FT sensors that enable precise separation of the force and torque components without the need for additional devices or sensors by estimating essential parameters: bias, crosstalk, CoM (center of mass), and inclination. By directly utilizing manufacturer-provided data, our approach eliminates the complexities of traditional calibration processes while achieving higher accuracy in force–torque measurements. This method simplifies the calibration workflow and enhances the practicality of FT sensor applications. A mobile manipulator installed with an FT sensor and a gripper is used to demonstrate calibration effectiveness across varying postures and incline conditions, with non-linear optimization based on the gradient descent method applied to minimize sensor-data errors. The tilt of the base is implemented by placing a step under the wheels of the mobile base to simulate roll or pitch scenarios. A digital level was used to measure the angle and verify that our predicted results were accurate. The proposed method addresses typical calibration challenges, including the effects of the end tool and base incline, which are not commonly covered in existing methods. The results show that, on a non-inclined base, crosstalk and CoM calibration reduces the MSE (mean squared error) by 55.8%, 56.2%, and 14.5% for the external force with respect to data without any calibration conducted. On an inclined base, our full calibration process reduces the MSE by a maximum of 98.6% for external mass measurement with respect to no calibration method applied. These findings highlight the importance of incline calibration for achieving accurate external force estimations, especially in mobile manipulator applications where the environment frequently changes.