Digital speckle correlation (DSC) solves the problem of searching corresponding points between two images, and it shows great application potential in pattern-projection based fast 3D shape measurement, because only one shot is enough to retrieve the 3D structure. As DSC relies on analyzing the spatial intensity distribution of a subset in image with a given point, it is likely to get false correspondences in low quality DSC area such as the background, because the searching range is hard to locate. So it is still hard to use DSC to realize fast 3D shape measurement. To solve this problem, the gray standard deviation of the subset is designed to recognize and remove the low-quality DSC area, and the principle of epipolar geometry and disparity constraint are utilized to determine the searching range, so the correspondences can be obtained. Moreover, in order to enhance the robustness of this method, a connected region method based on neighboring pixels possessing similar disparity is proposed to remove mismatched points after establishing initial disparity map by correspondences. Once the disparity map is obtained 3D structure can be retrieved based on the triangulation principle. The experiment on reconstructing Gorky plaster statue is performed, verifying that the proposed method can substantially reduce mismatched points and achieve robust single frame 3D shape measurement.
3D Visual Inspection for high-temperature objects has attracted more and more attention in the industrial and manufacture field. Until now it is still difficult to measure the shape of high-temperature objects due to the following problems: 1) the radiation and heat transfer through the air seriously affect both human and measurement equipment, so the manual measurement is not capable in this situation. 2) Because of the difficulties to handle the surfaces of the hot objects, it is hard to use artificial markers to align different pieces of data. In order to solve these problems, an automatic 3D shape measurement system for high-temperature objects is proposed by combing an industrial robot with a structured blue light 3D scanner. In this system, the route for inspection is planned with the cooled object and then executed automatically with the same object in hot state to avoid artificial operations. The route is carefully planned to reduce the exposure time of the measurement equipment under the high-temperature situation. Then different pieces of data are premapped during the planning procedure. In the executing procedure, they can be aligned accurately thanks to the good repeatability of the industrial robot. Finally, different pieces of data are merged without artificial markers and the results are better than methods with traditional hand-eye calibration. Experiments verify that the proposed system can conduct the inspection of forging parts under the temperature of 900°C and the alignment precision is 0.0013rad and 0.28mm.
Measuring high-reflective surfaces using optical method is always a big challenging problem. This paper presents a high-reflective surface measurement method based on conoscopic holography technology using a 4D motion platform equipped with a conoscopic holography optical probe. There are two key problems needed to solve before the automate scan of the complex shape surface: the coordinate calibration and the path planning. To improve the calibration efficiency and accuracy, the coordinate calibration is divided into two parts: the rough calibration and the accurate registration. The path planning consists of two aspects including: the path points generation and the path points verification. In addition, by scanning the objects having high-reflective surfaces, such as the metal blades, coins and other work-pieces, the efficiency of the measurement method has been verified.
Fast and precise 3D inspection system is in great demand in modern manufacturing processes. At present, the available sensors have their own pros and cons, and hardly exist an omnipotent sensor to handle the complex inspection task in an accurate and effective way. The prevailing solution is integrating multiple sensors and taking advantages of their strengths. For obtaining a holistic 3D profile, the data from different sensors should be registrated into a coherent coordinate system. However, some complex shape objects own thin wall feather such as blades, the ICP registration method would become unstable. Therefore, it is very important to calibrate the extrinsic parameters of each sensor in the integrated measurement system. This paper proposed an accurate and automatic extrinsic parameter calibration method for blade measurement system integrated by different optical sensors. In this system, fringe projection sensor (FPS) and conoscopic holography sensor (CHS) is integrated into a multi-axis motion platform, and the sensors can be optimally move to any desired position at the object’s surface. In order to simple the calibration process, a special calibration artifact is designed according to the characteristics of the two sensors. An automatic registration procedure based on correlation and segmentation is used to realize the artifact datasets obtaining by FPS and CHS rough alignment without any manual operation and data pro-processing, and then the Generalized Gauss-Markoff model is used to estimate the optimization transformation parameters. The experiments show the measurement result of a blade, where several sampled patches are merged into one point cloud, and it verifies the performance of the proposed method.