Eccentricity error identification and compensation for high-accuracy 3D optical measurement

High-accuracy camera calibration method based on coded concentric ring center extraction

In the field of three-dimensional (3-D) metrology based on fringe projection profilometry (FPP), accurate camera calibration is an essential task and a primary requirement. In order to improve the accuracy of camera calibration, the calibration board or calibration target needs to be manufactured with high accuracy, and the marker points in calibration image require to be positioned with high accuracy. This paper presents an improved camera calibration method by simultaneously optimizing the camera parameters and target geometry. Specifically, a set of regularly distributed target markers with rich coded concentric ring pattern is first displayed on a liquid crystal display (LCD) screen. Then, the sub-pixel edges of all coded bands radial straight lines are automatically located at several positions of the LCD screen. Finally, the sub-pixel edge point set is mapped into parameter space to form a line set, and the intersection of the lines is defined as the center pixel coordinates of each target point to complete the camera calibration. The simulation and experimental results verify that the proposed camera calibration method is feasible and easy to operate, which can essentially eliminate the perspective transformation error to improve the accuracy of camera parameters and target geometry.

A Novel Concentric Circular Coded Target, and Its Positioning and Identifying Method for Vision Measurement under Challenging Conditions

Coded targets have been demarcated as control points in various vision measurement tasks such as camera calibration, 3D reconstruction, pose estimation, etc. By employing coded targets, matching corresponding image points in multi images can be automatically realized which greatly improves the efficiency and accuracy of the measurement. Although the coded targets are well applied, particularly in the industrial vision system, the design of coded targets and its detection algorithms have encountered difficulties, especially under the conditions of poor illumination and flat viewing angle. This paper presents a novel concentric circular coded target (CCCT), and its positioning and identifying algorithms. The eccentricity error has been corrected based on a practical error-compensation model. Adaptive brightness adjustment has been employed to address the problems of poor illumination such as overexposure and underexposure. The robust recognition is realized by perspective correction based on four vertices of the background area in the CCCT local image. The simulation results indicate that the eccentricity errors of the larger and smaller circles at a large viewing angle of 70° are reduced by 95% and 77% after correction by the proposed method. The result of the wing deformation experiment demonstrates that the error of the vision method based on the corrected center is reduced by up to 18.54% compared with the vision method based on only the ellipse center when the wing is loaded with a weight of 6 kg. The proposed design is highly applicable, and its detection algorithms can achieve accurate positioning and robust identification even in challenging environments.

Iterative calibration method for measurement system having lens distortions in fringe projection profilometry

In fringe projection profilometry, system calibration is crucial for guaranteeing the measurement accuracies. Its difficulty lies in calibrating projector parameters, especially when the projector lens has distortions, since the projector, unlike a camera, cannot capture images, leading to an obstacle to knowing the correspondences between its pixels and object points. For solving this issue, this paper, exploiting the fact that the fringe phases on a plane board theoretically have a distribution of rational function, proposes an iterative calibration method based on phase measuring. Projecting fringes onto the calibration board and fitting the measured phases with a rational function allow us to determine projector pixels corresponding to the featured points on the calibration board. Using these correspondences, the projector parameters are easy to estimate. Noting that the projector lens distortions may deform the fitted phase map thus inducing errors in the estimates of the projector parameters, this paper suggests an iterative strategy to overcome this problem. By implementing the phase fitting and the parameter estimating alternately, the intrinsic and extrinsic parameters of the projector, as well as its lens distortion coefficients, are determined accurately. For compensating for the effects of the lens distortions on measurement, this paper gives two solutions. The pre-compensation actively curves the fringes in computer when generating them; whereas when using the post-compensation, the lens distortion correction is performed in the data processing stage. Both methods are experimentally verified to be effective in improving the measurement accuracies.

Sub-pixel projector calibration method for fringe projection profilometry

Digital projectors are used as standard parts at present in fringe projection profilometry systems to project structured-light patterns onto the object surface to be measured, and the distortion of the projector lens must be calibrated and compensated accurately to satisfy the accuracy requirement of industrial applications. A novel method is proposed to determine the projector pixel coordinates of the marker points of a calibration target accurately in terms of projective transform. With the method, the projector can be calibrated with accuracy of sub-pixel level. The method is applicable for the calibration target with a chessboard pattern or a circle pattern, and the calibration result is independent on the results of camera calibration. Experimental results are shown to demonstrate the effectiveness and validity of the proposed method.

Rapid Global Calibration Technology for Hybrid Visual Inspection System

Vision-based methods for product quality inspection are playing an increasingly important role in modern industries for their good performance and high efficiency. A hybrid visual inspection system, which consists of an industrial robot with a flexible sensor and several stationary sensors, has been widely applied in mass production, especially in automobile manufacturing. In this paper, a rapid global calibration method for the hybrid visual inspection system is proposed. Global calibration of a flexible sensor is performed first based on the robot kinematic. Then, with the aid of the calibrated flexible sensor, stationary sensors are calibrated globally one by one based on homography. Only a standard sphere and an auxiliary target with a 2D planar pattern are applied during the system global calibration, and the calibration process can be easily re-performed during the system’s periodical maintenance. An error compensation method is proposed for the hybrid inspection system, and the final accuracy of the hybrid system is evaluated with the deviation and correlation coefficient between the measured results of the hybrid system and Coordinate Measuring Machine (CMM). An accuracy verification experiment shows that deviation of over 95% of featured points are less than ±0.3 mm, and the correlation coefficients of over 85% of points are larger than 0.7.

Multicamera system extrinsic stability analysis and large-span truss string structure displacement measurement

A novel technique for measuring the displacements of large-span truss string structures that employs multicamera systems is proposed. The coordinates of the stereo-vision systems are unified in a single global coordinate system by employing 3D data reconstructed using close-range photogrammetry. To estimate the camera's attitude motions during an experiment, an instantaneous extrinsic rectification algorithm was developed. Experiments in which a camera was rotated and translated were conducted to verify the accuracy and precision of the developed algorithm. In addition, the proposed multicamera systems were employed to analyze a large-span truss string structure. The displacement results obtained from numerical simulations and experiments using pre-calibration and rectification methods are compared in this paper, and the stability of the camera's extrinsic parameters is discussed.