A new one-time registration method was developed in this research for hand-eye calibration of a surgical robot to simplify the operation process and reduce the preparation time. And a new and practical method is introduced in this research to optimize the end-tool parameters of the surgical robot based on analysis of the error sources in this registration method. In the process with one-time registration method, firstly a marker on the end-tool of the robot was recognized by a fixed binocular camera, and then the orientation and position of the marker were calculated based on the joint parameters of the robot. Secondly the relationship between the camera coordinate system and the robot base coordinate system could be established to complete the hand-eye calibration. Because of manufacturing and assembly errors of robot end-tool, an error equation was established with the transformation matrix between the robot end coordinate system and the robot end-tool coordinate system as the variable. Numerical optimization was employed to optimize end-tool parameters of the robot. The experimental results showed that the one-time registration method could significantly improve the efficiency of the robot hand-eye calibration compared with the existing methods. The parameter optimization method could significantly improve the absolute positioning accuracy of the one-time registration method. The absolute positioning accuracy of the one-time registration method can meet the requirements of the clinical surgery.
