Calibration routine for a telecentric stereo vision system considering affine mirror ambiguity

A robust calibration approach for a telecentric stereo camera system for three-dimensional (3-D) surface measurements is presented, considering the effect of affine mirror ambiguity. By optimizing the parameters of a rigid body transformation between two marker planes and transforming the two-dimensional (2-D) data into one coordinate frame, a 3-D calibration object is obtained, avoiding high manufacturing costs. Based on the recent contributions in the literature, the calibration routine consists of an initial parameter estimation by affine reconstruction to provide good start values for a subsequent nonlinear stereo refinement based on a Levenberg–Marquardt optimization. To this end, the coordinates of the calibration target are reconstructed in 3-D using the Tomasi–Kanade factorization algorithm for affine cameras with Euclidean upgrade. The reconstructed result is not properly scaled and not unique due to affine ambiguity. In order to correct the erroneous scaling, the similarity transformation between one of the 2-D calibration plane points and the corresponding 3-D points is estimated. The resulting scaling factor is used to rescale the 3-D point data, which then allows in combination with the 2-D calibration plane data for a determination of the start values for the subsequent nonlinear stereo refinement. As the rigid body transformation between the 2-D calibration planes is also obtained, a possible affine mirror ambiguity in the affine reconstruction result can be robustly corrected. The calibration routine is validated by an experimental calibration and various plausibility tests. Due to the usage of a calibration object with metric information, the determined camera projection matrices allow for a triangulation of correctly scaled metric 3-D points without the need for an individual camera magnification determination

State-of-the-art active optical techniques for three-dimensional surface metrology: a review [Invited]

This paper reviews recent developments of non-contact three-dimensional (3D) surface metrology using an active structured optical probe. We focus primarily on those active non-contact 3D surface measurement techniques that could be applicable to the manufacturing industry. We discuss principles of each technology, and its advantageous characteristics as well as limitations. Towards the end, we discuss our perspectives on the current technological challenges in designing and implementing these methods in practical applications.Purdue Universit

High-quality 3D shape measurement with binarized dual phase-shifting method

ABSTRACT 3-D technology is commonplace in today\u27s world. They are used in many dierent aspects of life. Researchers have been keen on 3-D shape measurement and 3-D reconstruction techniques in past decades as a result of inspirations from dierent applications ranging from manufacturing, medicine to entertainment. The techniques can be broadly divided into contact and non-contact techniques. The contact techniques like coordinate measuring machine (CMM) dates way back to 1950s. It has been used extensively in the industries since then. It becomes predominant in industrial inspections owing to its high accuracy in the order of m. As we know that quality control is an important part of modern industries hence the technology is enjoying great popularity. However, the main disadvantage of this method is its slow speeds due to its requirement of point-by-point touch. Also, since this is a contact process, it might deform a soft object while performing measurements. Such limitations led the researchers to explore non-contact measurement technologies (optical metrology techniques). There are a variety of optical techniques developed till now. Some of the well-known technologies include laser scanners, stereo vision, and structured light systems. The main limitation of laser scanners is its limited speed due to its point-by-point or line-by-line scanning process. The stereo vision uses two cameras which take pictures of the object at two dierent angles. Then epipolar geometry is used to determine the 3-D coordinates of points in real-world. Such technology imitates human vision, but it had a few limitations too like the diculty of correspondence detection for uniform or periodic textures. Hence structured light systems were introduced which addresses the aforementioned limitations. There are various techniques developed including 2-D pseudo-random codication, binary codication, N-ary codication and digital fringe projection (DFP). The limitation of 2-D pseudo-random codication technique is its inability to achieve high spatial resolution since any uniquely generated and projected feature requires a span of several projector pixels. The binary codication techniques reduce the requirement of 2-D features to 1-D ones. However, since there are only two intensities, it is dicult to differentiate between the individual pixels within each black or white stripe. The other disadvantage is that n patterns are required to encode 2n pixels, meaning that the measurement speeds will be severely affected if a scene is to be coded with high-resolution. Dierently, DFP uses continuous sinusoidal patterns. The usage of continuous patterns addresses the main disadvantage of binary codication (i.e. the inability of this technique to differentiate between pixels was resolved by using sinusoid patterns). Thus, the spatial resolution is increased up to camera-pixel-level. On the other hand, since the DFP technique used 8-bit sinusoid patterns, the speed of measurement is limited to the maximum refreshing rate of 8-bit images for many video projectors (e.g. 120 Hz). This made it inapplicable for measurements of highly dynamic scenes. In order to overcome this speed limitation, the binary defocussing technique was proposed which uses 1-bit patterns to produce sinusoidal prole by projector defocusing. Although this technique has signicantly boosted the measurement speed up to kHz-level, if the patterns are not properly defocused (nearly focused or overly defocused), increased phase noise or harmonic errors will deteriorate the reconstructed surface quality. In this thesis research, two techniques are proposed to overcome the limitations of both DFP and binary defocusing technique: binarized dual phase shifting (BDPS) technique and Hilbert binarized dual phase shifting technique (HBDPS). Both techniques were able to achieve high-quality 3-D shape measurements even when the projector is not sufficiently defocused. The harmonic error was reduced by 47% by the BDPS method, and 74% by the HBDPS method. Moreover, both methods use binary patterns which preserve the speed advantage of the binary technology, hence it is potentially applicable to simultaneous high-speed and high-accuracy 3D shape measurements

Simple and accurate empirical absolute volume calibration of a multi-sensor fringe projection system

This paper suggests a novel absolute empirical calibration method for a multi-sensor fringe projection system. The optical setup of the projector-camera sensor can be arbitrary. The term absolute calibration here means that the centre of the three dimensional coordinates in the resultant calibrated volume coincides with a preset centre to the three-dimensional real-world coordinate system. The use of a zero-phase fringe marking spot is proposed to increase depth calibration accuracy, where the spot centre is determined with sub-pixel accuracy. Also, a new method is proposed for transversal calibration. Depth and transversal calibration methods have been tested using both single sensor and three-sensor fringe projection systems. The standard deviation of the error produced by this system is 0.25 mm. The calibrated volume produced by this method is 400 mm×400 mm×140 m

3D Shape Measurement of Objects in Motion and Objects with Complex Surfaces

This thesis aims to address the issues caused by high reflective surface and object with motion in the three dimensional (3D) shape measurement based on phase shifting profilometry (PSP). Firstly, the influence of the reflectivity of the object surface on the fringe patterns is analysed. One of the essential factors related to phase precision is modulation index, which has a direct relationship with the surface reflectivity. A comparative study focusing on the modulation index of different materials is presented. The distribution of modulation index for different material samples is statistically analysed, which leads to the conclusion that the modulation index is determined by the diffuse reflectivity. Then the method based on optimized combination of multiple reflected image patterns is proposed to address the saturation issue and improve the accuracy for the reconstruction of object with high reflectivity.A set of phase shifted sinusoidal fringe patterns with different exposure time are projected to the object and then captured by camera. Then a set of masks are generated to select the data for the compositing. Maximalsignal-to-noise ratio combining model is employed to form the composite images pattern. The composite images are then used to phase mapping.Comparing to the method only using the highest intensity of pixels for compositing image, the signal noise ratio (SNR) of composite image is increased due to more efficient use of information carried by the images