In the research, aiming at high positioning quality for LED chips under the variable system parameters, a real-time and robust visual positioning method is presented. At first, to solve the problems of delay in image system and measuring deviation in encoder, an adaptive dual rate Kalman filter technology is designed to estimate the accurate location of LED chip in real time. After sensitivity analysis, the changes of system parameters during manufacturing have a significant influence on estimation effect. Accordingly, an adaptive recursive least squares algorithm is integrated into the above estimation process to determine the system parameters timely and precisely. In the end, through experimental verification, the described method can guarantee the acceptable positioning effect and adapt to the variations of system parameters., Competing Interests: Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper., (Copyright © 2020 ISA. Published by Elsevier Ltd. All rights reserved.)