Non-contact free-form shape measurement for coordinate measuring machines

Precision measurement of manufactured parts commonly uses contact measurement methods. A Coordinate Measuring Machine (CMM) mounted probe touches the surface of the part, recording the probe’s tip position at each contact. Recently, devices have been developed that continuously scan the probe tip across the surface, allowing points to be measured more quickly. Contact measurement is accurate and fast for shapes that are easily parameterized such as a sphere or a plane, but is slow and requires considerable user input for more general objects such as those with free-form surfaces. Phase stepping fringe projection and photogrammetry are common non-contact shape measurement methods. Photogrammetry builds a 3D model of feature points from images of an object taken from multiple perspectives. In phase stepping fringe projection a series of sinusoidal patterns, with a phase shift between each, is projected towards an object. A camera records a corresponding series of images. The phase of the pattern at each imaged point is calculated and converted to a 3D representation of the object’s surface. Techniques combining phase stepping fringe projection and photogrammetry were developed and are described here. The eventual aim is to develop an optical probe for a CMM to enable non-contact measurement of objects in an industrial setting. For the CMM to accurately report its position the probe must be small, light, and robust. The methods currently used to provide a phase shift require either an accurately calibrated translation stage to move an internal component, or a programmable projector. Neither of these implementations can be practically mounted on a CMM due to size and weight limits or the delicate parts required. A CMM probe consisting of a single camera and a fringe projector was developed. The fringe projector projects a fixed fringe pattern. Phase steps are created by moving the CMM mounted probe, taking advantage of the geometry of the fringe projection system. New techniques to calculate phase from phase stepped images created by relative motion of probe and object are proposed, mathematically modelled, and tested experimentally. Novel techniques for absolute measurement of surfaces by viewing an object from different perspectives are developed. A prototype probe is used to demonstrate measurements of a variety of objects.Engineering and Physical Sciences Research Council (EPSRC) Grant No. GR/T11289/0

Micro Fourier Transform Profilometry (μ\muFTP): 3D shape measurement at 10,000 frames per second

Recent advances in imaging sensors and digital light projection technology have facilitated a rapid progress in 3D optical sensing, enabling 3D surfaces of complex-shaped objects to be captured with improved resolution and accuracy. However, due to the large number of projection patterns required for phase recovery and disambiguation, the maximum fame rates of current 3D shape measurement techniques are still limited to the range of hundreds of frames per second (fps). Here, we demonstrate a new 3D dynamic imaging technique, Micro Fourier Transform Profilometry ($\mu$FTP), which can capture 3D surfaces of transient events at up to 10,000 fps based on our newly developed high-speed fringe projection system. Compared with existing techniques, $\mu$FTP has the prominent advantage of recovering an accurate, unambiguous, and dense 3D point cloud with only two projected patterns. Furthermore, the phase information is encoded within a single high-frequency fringe image, thereby allowing motion-artifact-free reconstruction of transient events with temporal resolution of 50 microseconds. To show $\mu$FTP's broad utility, we use it to reconstruct 3D videos of 4 transient scenes: vibrating cantilevers, rotating fan blades, bullet fired from a toy gun, and balloon's explosion triggered by a flying dart, which were previously difficult or even unable to be captured with conventional approaches.Comment: This manuscript was originally submitted on 30th January 1

Uncertainty on fringe projection technique: a Monte-Carlo-based approach

International audienceError estimation on optical full field techniques (OFFT) is millstone in the diffusion of OFFT. The present work describes a generic way to estimate overall error in fringe projection, either due to random sources (phase error, basically related to the quality of the camera and of the fringe extraction algorithm) or the bias (calibration errors). Here, a high level calibration procedure based on pinhole model has been implemented. This model compensates for the divergence effects of both the video-projector and the camera. The work is based on a Monte Carlo procedure. So far, the complete models of the calibration procedure and of a reference experiment are necessary. Here, the reference experiment consists in multiple step out-of-plane displacement of a plane surface. Main conclusions of this work are: 1/ the uncertainties in the calibration procedure lead to a global rotation of the plane, 2/ the overall error has been calculated in two situations; the overall error ranges from 104 µm down to 10 µm, 3/ the main error source is the phase error even if errors due to the calibration are not always negligible

Development of a calibration pipeline for a monocular-view structured illumination 3D sensor utilizing an array projector

Commercial off-the-shelf digital projection systems are commonly used in active structured illumination photogrammetry of macro-scale surfaces due to their relatively low cost, accessibility, and ease of use. They can be described as inverse pinhole modelled. The calibration pipeline of a 3D sensor utilizing pinhole devices in a projector-camera setup configuration is already well-established. Recently, there have been advances in creating projection systems offering projection speeds greater than that available from conventional off-the-shelf digital projectors. However, they cannot be calibrated using well established techniques based on the pinole assumption. They are chip-less and without projection lens. This work is based on the utilization of unconventional projection systems known as array projectors which contain not one but multiple projection channels that project a temporal sequence of illumination patterns. None of the channels implement a digital projection chip or a projection lens. To workaround the calibration problem, previous realizations of a 3D sensor based on an array projector required a stereo-camera setup. Triangulation took place between the two pinhole modelled cameras instead. However, a monocular setup is desired as a single camera configuration results in decreased cost, weight, and form-factor. This study presents a novel calibration pipeline that realizes a single camera setup. A generalized intrinsic calibration process without model assumptions was developed that directly samples the illumination frustum of each array projection channel. An extrinsic calibration process was then created that determines the pose of the single camera through a downhill simplex optimization initialized by particle swarm. Lastly, a method to store the intrinsic calibration with the aid of an easily realizable calibration jig was developed for re-use in arbitrary measurement camera positions so that intrinsic calibration does not have to be repeated

Three-dimensional geometry characterization using structured light fields

Tese de doutoramento. Engenharia Mecânica. Faculdade de Engenharia. Universidade do Porto. 200

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

Correction of the fringe order errors for fringe projection profilometry

Non-contact three-dimensional (abbreviated as 3D) Fringe projection profilometry (abbreviated as FPP) counts as a method of reconstructing the shape of object surface. This technique has been extensively used in many areas, e.g. computer vision, biomedical research, industrial applications, and virtual reality. Using a FPP, sinusoidal patterns are projected on the object surface by mean of a digital projector, and subsequently a camera captures the reflected patterns deformed by the object surface. As the shape information of the object surface is carried by the deformed patterns, the 3D profile can be retrieved through analysing these patterns. The phase unwrapping is a primary issue bound by the existing phase unwrapping techniques in FPP, aiming to recover the absolute phase from wrapped phase. The temporal phase unwrapping with multi-frequency fringe pattern was proposed, prominently advantaged by none-error propagation. Furthermore, the fringe order is deemed as the critical property to retrieve the absolute phase