Area modulation grating for sinusoidal structure illumination on phase-measuring profilometry

Ultra-small, low-cost, and simple-to-control PSP projector based on SLCD technology

Demand for ultra-small, inexpensive, and high-accurate 3D shape measurement devices is growing rapidly, especially in the industrial and consumer electronics sectors. Phase shifting profilometry (PSP) is a powerful candidate due to its advantages of high accuracy, great resolution, and insensitivity to ambient light. As a key component in PSP, the projector used to generate the phase-shifting sinusoidal fringes must be ultra-small (several millimeters), low-cost, and simple to control. However, existing projection methods make it difficult to meet these requirements simultaneously. In this paper, we present a modern technique that can be used to fabricate the desired projector. A specifically designed device based on segmented liquid crystal display (SLCD) technology is used to display the projected patterns, and a cylindrical lens is used as the projection lens. The SLCD device can display four sets of specific filled binary patterns, each yielding a sinusoidal fringe, and all four sinusoidal fringes satisfy the four-step phase shift relation. 3D shape measurement experiments verify the performance of the projector. Considering that the size of SLCD devices can be reduced to a few millimeters, the proposed technique can be easily used to manufacture ultra-small, low-cost, and simple-to-control PSP projectors.

Temporal-spatial binary encoding method based on dynamic threshold optimization for 3D shape measurement

The binary encoding method has been widely used for three-dimensional (3D) shape measurement due to the high-speed projection characteristics of its digital mirror device (DMD)-based projector. However, traditional binary encoding methods require a larger defocus to achieve a good sinusoidality, leading to a reduction in the measurement depth of field and signal-to-noise ratio (SNR) of captured images, which can adversely affect the accuracy of phase extraction, particularly high-frequency fringes for 3D reconstruction. This paper proposes a spatial-temporal binary encoding method based on dynamic threshold optimization for 3D shape measurement. The proposed method decomposes an 8-bit sinusoidal fringe pattern into multiple(K) binary patterns, which can be outlined into two steps: determining the dynamic threshold and then performing temporal-spatial error diffusion encoding. By using an integral imaging strategy, approximate sinusoidal patterns can be obtained under nearly focused projection, which can then be subjected to absolute phase unwrapping and 3D reconstruction. The experiments show that compared to the three comparative algorithms under the same experimental conditions, this proposed method improves the reconstruction error of measuring a plane and an object by at least 13.66% and 12.57% when K=2. The dynamic experimental result on the palm confirms that the proposed method can reliably reconstruct the 3D shape of the moving object.

Improved 3D Pavement Texture Reconstruction Method Based on Interference Fringe via Optimizing the Post-Processing Method

The surface quality of pavement has a significant influence on the driving comfort and the skid resistance performance of roads. The 3D pavement texture measurement provides the basis for engineers to calculate the pavement performance index, such as the international roughness index (IRI), the texture depth (TD), and the rutting depth index (RDI), of different types of pavements. The interference-fringe-based texture measurement is widely used because of its high accuracy and high resolution, by which the 3D texture measurement has excellent accuracy in measuring the texture of workpieces with a diameter of <30 mm. When measuring the engineering products with a larger area (or larger areas), such as pavement surfaces, however, the accuracy is deficient because unequal incident angles due to the beam-divergence angle of the laser beam are ignored during the postprocessing of the measured data. This study aims to improve the accuracy of 3D pavement texture reconstruction based on the interference fringe (3D-PTRIF) by considering the influence of the unequal incident angles during postprocessing. It is found that the improved 3D-PTRIF has better accuracy than the traditional 3D-PTRIF, reducing the reconstruction errors between the measured value and the standard value by 74.51%. In addition, it solves the problem of a reconstructed slant surface, which deviates from the horizontal plane of the original surface. Compared to the traditional post-processing method, for the case of smooth surface, the slope can be decreased by 69.00%; for the case of coarse surface, the slope can be decreased by 15.29%. The results of this study will facilitate accurate quantifying of the pavement performance index by using the interference fringe technique, such as IRI, TD, and RDI.

High-efficiency and robust binary fringe optimization for superfast 3D shape measurement

By utilizing 1-bit binary fringe patterns instead of conventional 8-bit sinusoidal patterns, binary defocusing techniques have been successfully applied for high-speed 3D shape measurement. However, simultaneously achieving high accuracy and high speed remains challenging. To overcome this limitation, we propose a high-efficiency and robust binary fringe optimization method for superfast 3D shape measurement, which consists of 1D optimization and 2D modulation. Specifically, for 1D optimization, the three-level OPWM technique is introduced for high-order harmonics elimination, and an optimization framework is presented for generating the 'best' three-level OPWM pattern especially for large fringe periods. For 2D modulation, a single-pattern three-level OPWM strategy is proposed by utilizing all the dimensions for intensity modulation to decrease the required projection patterns. Thus, the proposed method essentially belongs to the 2D modulation technique, yet iterative optimization is carried out along one dimension, which drastically improves the computational efficiency while ensuring high accuracy. With only one set of optimized patterns, both simulations and experiments demonstrate that high-quality phase maps can be consistently generated for a wide range of fringe periods (e.g., from 18 to 1140 pixels) and different amounts of defocusing, and it can achieve superfast and high-accuracy 3D shape measurement.

High-speed 3D shape measurement using a rotary mechanical projector

In this paper, a fast rotary mechanical projector (RMP) is designed and manufactured for high-speed 3D shape measurement. Compared with the common high-speed projectors, RMP has a good performance in high-speed projection, which can obtain high quality projected fringes with shorter camera exposure time by using the error diffusion binary coding method and chrome plating technology. The magnitude, acceptability of systemic projection error is analyzed and quantified in detail. For the quantified error, the probability distribution function (PDF) algorithm is introduced to correct the error. Corrected projection error is reduced to more than one third of the original error. Subsequently, a monocular measurement system composed of the RMP and a single camera is constructed. The combination of the RMP device and PDF algorithm ensure the accuracy of a corresponding 3D shape measurement system. Experiments have demonstrated that the proposed solution has a good performance for the 3D measurement of high-speed scenes.

Improved computer-generated moiré profilometry with flat image calibration

An improved computer-generated moiré profilometry (CGMP) with flat image calibration is proposed. In CGMP, the purification of the AC component plays a decisive role. While a composite grating modulated with both the sinusoidal grating and its background light substitutes for the sinusoidal grating itself, the sinusoidal deformed pattern and flat image can be demodulated from the captured pattern. It is found that the sinusoidal deformed pattern and flat image may deviate, which is caused by ambient light. So flat image calibration is conducted to obtain a purer AC component that can effectively suppress the influence of ambient light and ensure the measurement accuracy, even if spectrum aliasing exists. Experimental results show the feasibility and validity of the proposed method.

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.

Multi-Field Interference Simultaneously Imaging on Single Image for Dynamic Surface Measurement

To obtain the dynamic surface of high-frequency vibrating mirrors (VMs), a novel method involving multi-field interference (MFI) pattern imaging on a single image is proposed in this paper. Using multiple reflections and refractions, the proposed method generates three interference patterns at the same time, which improves the traditional time-series methods where a single interference pattern can be obtained at one time. Experimental results show that a series of MFI patterns can be obtained on a single image, with the laser repetition frequency (LRF) ranging from 200 Hz to 10 Hz, and the frame rate of the camera at 10 Hz. Particularly if the LRF (10 Hz) is equal to the frame rate of image, crosstalk is avoided completely, which is particularly desirable in dynamic surface measurement. In summary, the MFI imaging method provides an effective way for VM dynamic surface measurement.

Long Exposure Short Pulse Synchronous Phase Lock Method for Capturing High Dynamic Surface Shape

In infrared weak target detection systems, high-frequency vibrating mirrors (VMs) are a core component. The dynamic surface shape of the VM has a direct impact on imaging quality and the optical modulation effect, so its measurement is necessary but also very difficult. Measurement of the dynamic surface shape of VMs requires a transiently acquired image series, but traditional methods cannot perform this task, as, when the VM is vibrating at a frequency of 3033 Hz, using high-speed cameras to acquire the images would result in frame rates exceeding 1.34 MFPS, which is currently technically impossible. In this paper, we propose the long exposure short pulse synchronous phase lock (LSPL) method, which can capture the dynamic surface shape using a camera working at 10 FPS. In addition, our proposed approach uses a single laser pulse and can achieve the dynamic surface shape measurement on a single frame image.

Depth range enhancement of binary defocusing technique based on multi-frequency phase merging

Binary defocusing technique has demonstrated various merits for high-speed and high-accuracy three-dimensional measurement. However, the existence of excessive defocusing zone (EDZ) limits the depth range of binary defocusing system. To overcome this problem, this paper proposes a multi-frequency phase merging (MFPM) approach, which makes it possible to measure the object surface in large depth range (LDR). The method is based on our finding that for different fringe frequencies, the associated EDZs of binary defocusing system are different and not totally overlapped. Thus by merging the phase maps of multiple binary fringes, we could effectively enhance the measurement depth range. Meanwhile, a strategy to determine the optimal combination of fringe frequencies is also proposed by analyzing the phase error distribution under different defocusing degrees. Both simulations and experiments verify the effectiveness and robustness of the proposed method.

Double-pattern triangular pulse width modulation technique for high-accuracy high-speed 3D shape measurement

Using 1-bit binary patterns for three-dimensional (3D) shape measurement has been demonstrated as being advantageous over using 8-bit sinusoidal patterns in terms of achievable speeds. However, the phase quality generated by binary pattern(s) typically are not high if only a small number of phase-shifted patterns are used. This paper proposes a method to improve the phase quality by representing each pattern with the difference of two binary patterns: the first binary pattern is generated by triangular pulse width modulation (TPWM) technique, and the second being π shifted from the first pattern that is also generated by TPWM technique. The phase is retrieved by applying a three-step phase-shifting algorithm to the difference patterns. Through optimizing the modulation frequency of the triangular carrier signal, we demonstrate that a high-quality phase can be generated for a wide range of fringe periods (e.g., from 18 to 1140 pixels) with only six binary patterns. Since only 1-bit binary patterns are required for 3D shape measurement, this paper will present a real-time 3D shape measurement system that can achieve 30 Hz.

Nondestructive determination of optical properties of a pear using spatial frequency domain imaging combined with phase-measuring profilometry

Spatial frequency domain imaging (SFDI), as a rapid, noncontact, and scan-free method, can realize wide-field, quantitative optical property mapping and tomographic imaging for a biological sample. Phase-measuring profilometry (PMP) is a surface profile characterization method. Since the projection of structured light onto an object is the basis for PMP and SFDI, the SFDI system is capable of performing both techniques. In this work, we present the results of a feasibility study with the developed SFDI system to realize acquisition of the optical property information and the surface profile information. The surface profile information was used to correct the absorption (μ_a) maps and reduced scattering (μs') maps. The evaluation of correction effect of the PMP and the calibration and calculation of detection accuracy of the SFDI system were realized by using a series of self-made hemispheric and homogeneous solid phantoms covering a wide range of absorption and reduced scattering coefficients. The results show that the μ_a and μs' maps become more uniform after using profilometry correction. The maximum relative errors of the system after profilometry correction and calibration were 8.74% for μ_a and 4.97% for μs' at the wavelength of 527 nm, respectively. A case study was carried out on a pear to verify the application prospect of the method in the field of agricultural products quality inspection. Results indicate that μ_a and μs' maps of a pear after profilometry correction and calibration were more uniform and more comparable with the reported values.

Three-dimensional absolute shape measurement by combining binary statistical pattern matching with phase-shifting methods

This paper presents a novel method that leverages the stereo geometric relationship between projector and camera for absolute phase unwrapping on a standard one-projector and one-camera structured light system. Specifically, we use only one additional binary random image and the epipolar geometric constraint to generate a coarse correspondence map between projector and camera images. The coarse correspondence map is further refined by using the wrapped phase as a constraint. We then use the refined correspondence map to determine a fringe order for absolute phase unwrapping. Experimental results demonstrated the success of our proposed method.

Genetic method to optimize binary dithering technique for high-quality fringe generation

The recently proposed dithering techniques could substantially improve measurement quality when fringes are wide, but offer limited improvement when fringes are narrow. This Letter presents a genetic algorithm to optimize the dithering technique for sinusoidal structured pattern representation. We believe both simulation and experimental results show that this proposed algorithm can substantially improve fringe quality for both narrow and wide fringe patterns.

Three-dimensional shape measurement with binary dithered patterns

The previously proposed binary defocusing technique and its variations have proven successful for high-quality three-dimensional (3D) shape measurement when fringe stripes are relatively narrow, but they suffer if fringe stripes are wide. This paper proposes to utilize the binary dithering technique to conquer this challenge. Both simulation and experimental results show the phase error is always less than 0.6% even when the fringe stripes are wide and the projector is nearly focused.

Phase errors due to speckles in laser fringe projection

When measuring a three-dimensional shape with triangulation and projected interference fringes it is of interest to reduce speckle contrast without destroying the coherence of the projected light. A moving aperture is used to suppress the speckles and thereby reduce the phase error in the fringe image. It is shown that the phase error depends linearly on the ratio between the speckle contrast and the modulation of the fringes. In this investigation the spatial carrier method was used to extract the phase, where the phase error also depends on filtering the Fourier spectrum. An analytical expression for the phase error is derived. Both the speckle reduction and the theoretical expressions for the phase error are verified by simulations and experiments. It was concluded that a movement of the aperture by three aperture diameters during exposure of the image reduces the speckle contrast and hence the phase error by 60%. In the experiments, a phase error of 0.2 rad was obtained.

Fringe projection with a sinusoidal phase grating

Phase-shifting profilometry requires projection of sinusoidal fringes on a 3D object. We analyze the visibility and frequency content of fringes created by a sinusoidal phase grating at coherent illumination. We derive an expression for the intensity of fringes in the Fresnel zone and measure their visibility and frequency content for a grating that has been interferometrically recorded on a holographic plate. Both evaluation of the systematic errors due to the presence of higher harmonics by simulation of a profilometric measurement and measurement of 3D coordinates of test objects confirm the good performance of the sinusoidal phase grating as a projective element. In addition, we prove theoretically that in comparison with a sinusoidal amplitude grating this grating produces better quality of fringes in the near-infrared region. Sinusoidal phase gratings are fabricated easily, and their implementation in fringe projection profilometry facilitates construction of portable, small size, and low-cost devices.

Two-dimensional phase-measuring profilometry

An improved method is proposed to perform contouring of an object based on phase-measuring profilometry with a grid grating. Two phases unwrapped in perpendicular directions are obtained with the help of an adaptive bandpass filter and are used to unwrap the phases and to appoint the edge points of a shaded area and the object area. The height distribution of the object is obtained with the geometric relationship between coordinates and phases. The main axis of the projector and the main axis of the camera are not crossed and are also not in the same plane in order to arrange a measuring system easily and conveniently. The experimental results show that this technique is available for practical applications.