3D inspection methods for specular or partially specular surfaces

Deflectometric techniques are a powerful tool for the automated quality control of specular or shiny surfaces. These techniques are based on using a camera to observe a reference pattern reflected on the surface under inspection, exploiting the dependence of specular reflections on surface normals to recover shape information from the acquired images. Although deflectometry is already used in industrial environments such as the quality control of lenses or car bodies, there are still some open problems. On the one hand, using quantitative deflectometry, the normal vector field and the 3D shape of a surface can be obtained, but these techniques do not yet take full advantage of their local sensitivity because the achieved global accuracies are affected by calibration errors. On the other hand, qualitative deflectometry is used to detect surface imperfections without absolute measurements, exploiting the local sensitivity of deflectometric recordings with reduced calibration requirements. However, this qualitative approach requires further processing that can involve a considerable engineering effort, particularly for aesthetic defects which are inherently subjective. The first part of this thesis aims to contribute to a better understanding of how deflectometric setups and their calibration errors affect quantitative measurements. Different error sources are considered including the camera calibration uncertainty and several non-ideal characteristics of LCD screens used to generate the light patterns. Experiments performed using real measurements and simulations show that the non-planarity of the LCD screen and the camera calibration are the dominant sources of error. The second part of the thesis investigates the use of deep learning to identify geometrical imperfections and texture defects based on deflectometric data. Two different approaches are explored to extract and combine photometric and geometric information using convolutional neural network architectures: one for automated classification of defective samples, and another one for automated segmentation of defective regions in a sample. The experimental results in a real industrial case study indicate that both architectures are able to learn relevant features from deflectometric data, enabling the classification and segmentation of defects based on a dataset of user-provided examples.Teknika deflektometrikoak tresna baliotsuak dira gainazal espekular edo distiratsuen kalitate kontrol automatikoa gauzatzeko. Teknika hauetan, kamera bat erabiltzen da ikuskatu beharreko gainazalean islatutako erreferentziazko patroi bat behatzeko, eta isladapen espekularrek gainazalen bektore normalengan duten menpekotasuna ustiatzen dute irudietatik informazio geometrikoa berreskuratzeko. Zenbait industria-aplikaziotan deflektometria jada erabiltzen bada ere –adibidez, betaurrekoen edo autoen karrozerien kalitate kontrolean-, oraindik badaude hobetu beharreko hainbat esparru. Batetik, deflektometria kuantitatiboak aukera ematen du gainazal baten bektore-eremu normala eta 3D forma lortzeko, baina gaur egun teknika hauek ez dute beren sentsibilitate lokal guztia aprobetxatzen kalibrazio-akatsek zehaztasun globalean duten eraginagatik. Bestetik, deflektometria kualitatiboa neurketa absoluturik egin gabe gainazal akatsak antzemateko erabili daiteke, kalibrazio-eskakizun murriztuekin sentsibilitate lokala ustiatuz. Hala ere, teknika horiek algoritmoen garapenean esfortzu handia ekar dezakeen prozesamendu bat eskatzen dute, bereziki bere baitan subjektiboak diren akats estetikoetarako. Hala ere, teknika horiek algoritmoen garapenean esfortzu handia ekar dezakeen prozesamendu bat eskatzen dute, bereziki bere baitan subjektiboak diren akats estetikoetarako. Tesi honen lehen zatiaren helburua adkizizio sistema osatzen duten gailuek eta horien kalibrazioek neurketa kuantitatiboei nola eragiten dieten hobeto ulertzen laguntzea da. Hainbat errore-iturri hartzen dira kontuan, besteak beste kameraren kalibrazioaren ziurgabetasuna, eta argi-patroiak sortzeko erabilitako LCD pantailen zenbait ezaugarri ez-ideal. Neurketa errealetan eta simulazioetan egindako esperimentuek erakusten dute LCD pantailaren deformazioak eta kameraren kalibrazioak eragindako erroreak direla neurketen akats eta ziurgabetasun iturri nagusiak. Tesiaren bigarren zatian, datu deflektometrikoetatik abiatuz, inperfekzio geometrikoak eta testura-akatsak identifikatzeko ikaskuntza sakoneko metodoen erabilera ikertzen da. Helburu honekin, irudietatik informazio fotometrikoa eta geometrikoa atera eta konbinatzen duten sare neuronal konboluzionaletan oinarritutako bi arkitektura proposatzen dira: bata, lagin akastunak automatikoki sailkatzeko; eta, bestea, laginetako eremu akastunak automatikoki segmentatzeko. Automobilgintza industriako kasu praktiko baten lortutako emaitzek erakusten dute erabilitako arkitekturek datu deflektometrikoetatik ezaugarri esanguratsuak ikas ditzaketela, erabiltzaileak emandako adibide multzo batean oinarrituta gainazal akatsak sailkatu eta segmentatzea ahalbidetuz.Las técnicas deflectométricas son una herramienta valiosa para automatizar el control de calidad de superficies especulares o reflectantes. Estas técnicas se basan en el uso de una cámara para observar un patrón de referencia reflejado en la superficie bajo inspección, explotando la dependencia de los reflejos especulares en la normal de la superficie para recuperar información geométrica a partir de las imágenes adquiridas. Aunque la deflectometría ya se usa en algunas aplicaciones industriales, tales como el control de calidad de lentes o carrocerías de coches, todavía hay algunos problemas abiertos. Por un lado, la deflectometría cuantitativa permite obtener el campo vectorial normal y la forma 3D de una superficie, pero a día de hoy no es capaz de aprovechar al máximo su sensibilidad local ya que la precisión global se ve afectada por errores de calibración. Por otro lado, la deflectometría cualitativa se utiliza para detectar imperfecciones de la superficie sin mediciones absolutas, explotando la sensibilidad local de la deflectometría con requisitos de calibración reducidos. Sin embargo, estos métodos requieren un procesamiento adicional que puede implicar un esfuerzo considerable en el desarrollo de algoritmos, particularmente para defectos estéticos que son inherentemente subjetivos. La primera parte de esta tesis tiene como objetivo contribuir a una mejor comprensión de cómo el sistema de adquisición y su calibración afectan a las mediciones cuantitativas. Se consideran dife-rentes fuentes de error, incluida la incertidumbre de calibración de la cámara y varias características no ideales de las pantallas LCD utilizadas para generar los patrones de luz. Los experimentos realizados con mediciones reales y simulaciones indican que los errores inducidos por la deformación de la pantalla LCD y la calibración de la cámara son las principales fuentes de error e incertidumbre. La segunda parte de la tesis investiga el uso del aprendizaje profundo para identificar imperfecciones geométricas y defectos de textura a partir de datos deflectométricos. Se adoptan dos enfoques diferentes para extraer y combinar información fotométrica y geométrica utilizando sendas arquitecturas basadas en redes neuronales convolucionales: una para la clasificación automatizada de muestras defectuosas y otra para la segmentación automatizada de regiones defectuosas en una muestra. Los resultados experimentales en un caso de estudio industrial real indican que ambas arquitecturas pueden aprender características relevantes de los datos deflectométricos, permitiendo la clasificación y segmentación de defectos en base a un conjunto de datos de ejemplos proporcionados por el usuario

Proceedings of the 2011 Joint Workshop of Fraunhofer IOSB and Institute for Anthropomatics, Vision and Fusion Laboratory

This book is a collection of 15 reviewed technical reports summarizing the presentations at the 2011 Joint Workshop of Fraunhofer IOSB and Institute for Anthropomatics, Vision and Fusion Laboratory. The covered topics include image processing, optical signal processing, visual inspection, pattern recognition and classification, human-machine interaction, world and situation modeling, autonomous system localization and mapping, information fusion, and trust propagation in sensor networks

Modeling the unified measurement uncertainty of deflectometric and plenoptic 3-D sensors

In this paper we propose new models of two complementary optical sensors to obtain 2.5-D measurements of opaque surfaces: a deflectometric and a plenoptic sensor. The deflectometric sensor uses active triangulation and works best on specular surfaces, while the plenoptic sensor uses passive triangulation and works best on textured, diffusely reflecting surfaces. We propose models to describe the measurement uncertainties of the sensors for specularly to diffusely reflecting surfaces under consideration of typical disturbances like ambient light or vibration. The predicted measurement uncertainties of both sensors can be used to obtain optimized measurements uncertainties for varying surface properties on the basis of a combined sensor system. The models are validated exemplarily based on real measurements.</p

Modeling the unified measurement uncertainty of deflectometric and plenoptic 3-D sensors

In this paper we propose new models of two complementary optical sensors to obtain 2.5-D measurements of opaque surfaces: a deflectometric and a plenoptic sensor. The deflectometric sensor uses active triangulation and works best on specular surfaces, while the plenoptic sensor uses passive triangulation and works best on textured, diffusely reflecting surfaces. We propose models to describe the measurement uncer- tainties of the sensors for specularly to diffusely reflecting surfaces under consideration of typical disturbances like ambient light or vibration. The predicted measurement uncertainties of both sensors can be used to obtain optimized measurements uncertainties for varying surface properties on the basis of a combined sensor system. The models are validated exemplarily based on real measurements

Proceedings of the 2010 Joint Workshop of Fraunhofer IOSB and Institute for Anthropomatics, Vision and Fusion Laboratory

On the annual Joint Workshop of the Fraunhofer IOSB and the Karlsruhe Institute of Technology (KIT), Vision and Fusion Laboratory, the students of both institutions present their latest research findings on image processing, visual inspection, pattern recognition, tracking, SLAM, information fusion, non-myopic planning, world modeling, security in surveillance, interoperability, and human-computer interaction. This book is a collection of 16 reviewed technical reports of the 2010 Joint Workshop

Proceedings of the 2009 Joint Workshop of Fraunhofer IOSB and Institute for Anthropomatics, Vision and Fusion Laboratory

The joint workshop of the Fraunhofer Institute of Optronics, System Technologies and Image Exploitation IOSB, Karlsruhe, and the Vision and Fusion Laboratory (Institute for Anthropomatics, Karlsruhe Institute of Technology (KIT)), is organized annually since 2005 with the aim to report on the latest research and development findings of the doctoral students of both institutions. This book provides a collection of 16 technical reports on the research results presented on the 2009 workshop

Forum Bildverarbeitung 2020

Image processing plays a key role for fast and contact-free data acquisition in many technical areas, e.g., in quality control or robotics. These conference proceedings of the “Forum Bildverarbeitung”, which took place on 26.-27.11.202 in Karlsruhe as a common event of the Karlsruhe Institute of Technology and the Fraunhofer Institute of Optronics, System Technologies and Image Exploitation, contain the articles of the contributions

Material Recognition Meets 3D Reconstruction : Novel Tools for Efficient, Automatic Acquisition Systems

For decades, the accurate acquisition of geometry and reflectance properties has represented one of the major objectives in computer vision and computer graphics with many applications in industry, entertainment and cultural heritage. Reproducing even the finest details of surface geometry and surface reflectance has become a ubiquitous prerequisite in visual prototyping, advertisement or digital preservation of objects. However, today's acquisition methods are typically designed for only a rather small range of material types. Furthermore, there is still a lack of accurate reconstruction methods for objects with a more complex surface reflectance behavior beyond diffuse reflectance. In addition to accurate acquisition techniques, the demand for creating large quantities of digital contents also pushes the focus towards fully automatic and highly efficient solutions that allow for masses of objects to be acquired as fast as possible. This thesis is dedicated to the investigation of basic components that allow an efficient, automatic acquisition process. We argue that such an efficient, automatic acquisition can be realized when material recognition "meets" 3D reconstruction and we will demonstrate that reliably recognizing the materials of the considered object allows a more efficient geometry acquisition. Therefore, the main objectives of this thesis are given by the development of novel, robust geometry acquisition techniques for surface materials beyond diffuse surface reflectance, and the development of novel, robust techniques for material recognition. In the context of 3D geometry acquisition, we introduce an improvement of structured light systems, which are capable of robustly acquiring objects ranging from diffuse surface reflectance to even specular surface reflectance with a sufficient diffuse component. We demonstrate that the resolution of the reconstruction can be increased significantly for multi-camera, multi-projector structured light systems by using overlappings of patterns that have been projected under different projector poses. As the reconstructions obtained by applying such triangulation-based techniques still contain high-frequency noise due to inaccurately localized correspondences established for images acquired under different viewpoints, we furthermore introduce a novel geometry acquisition technique that complements the structured light system with additional photometric normals and results in significantly more accurate reconstructions. In addition, we also present a novel method to acquire the 3D shape of mirroring objects with complex surface geometry. The aforementioned investigations on 3D reconstruction are accompanied by the development of novel tools for reliable material recognition which can be used in an initial step to recognize the present surface materials and, hence, to efficiently select the subsequently applied appropriate acquisition techniques based on these classified materials. In the scope of this thesis, we therefore focus on material recognition for scenarios with controlled illumination as given in lab environments as well as scenarios with natural illumination that are given in photographs of typical daily life scenes. Finally, based on the techniques developed in this thesis, we provide novel concepts towards efficient, automatic acquisition systems

A Novel Active Imaging Model to Design Visual Systems: A Case of Inspection System for Specular Surfaces

The use of visual information is a very well known input from different kinds of sensors. However, most of the perception problems are individually modeled and tackled. It is necessary to provide a general imaging model that allows us to parametrize different input systems as well as their problems and possible solutions. In this paper, we present an active vision model considering the imaging system as a whole (including camera, lighting system, object to be perceived) in order to propose solutions to automated visual systems that present problems that we perceive. As a concrete case study, we instantiate the model in a real application and still challenging problem: automated visual inspection. It is one of the most used quality control systems to detect defects on manufactured objects. However, it presents problems for specular products. We model these perception problems taking into account environmental conditions and camera parameters that allow a system to properly perceive the specific object characteristics to determine defects on surfaces. The validation of the model has been carried out using simulations providing an efficient way to perform a large set of tests (different environment conditions and camera parameters) as a previous step of experimentation in real manufacturing environments, which more complex in terms of instrumentation and more expensive. Results prove the success of the model application adjusting scale, viewpoint and lighting conditions to detect structural and color defects on specular surfaces