Slight improvement

Instead of discarding what I've already done I decided to try getting a better calibration with linear fitting. The way it works right now is I've mounted a target on the robot arm, and using forward kinematics I know where the target is located in the robot arm's coordinate system. From the SR-3000 I can find the target (currently done by human), so I have correlated points from two coordinate systems. All that's left is to linear least-squares solve to find the transformation between the two.

Today I added some calibration targets on the ground plane (a wooden board) that correspond to a height of zero. The reason for this is that yesterday, targets low to the ground were very poorly aligned (2-3 cm off). I thought one reason might be because the target was mounted somewhat high on the robot arm, so any skew happening down low was missed.

The end result is that it works somewhat better. It's still off by an average of 0.5 cm I'd say, but it appears to be consistent. With the "guess and check" method I could align it for one setup where two blocks were about 0.2 cm off, but the third would be 2 cm off. When I changed the setup, everything ended up being off by 1 cm or more. I think if I sample just the right space, and then keep all items of interest in that space, I may not have to worry about nonlinear distortion so much. After all, everything's linear in the limit, right? :)