Hyper thin 3D edge measurement of honeycomb core structures based on the triangular camera-projector layout & phase-based stereo matching

High precision measurement for the chamfered hole radius and spacing of a large-size workpiece based on binocular vision combined with plane dynamic adjustment

A novel, to the best of our knowledge, hole radius and spacing measurement method is presented based on binocular vision combined with dynamic local plane for the large-size workpiece with plane feature. The novel method overcomes the problem of the ariable working distance and large location error of an abrupt edge for conventional methods. Its measurement principle and model are introduced. Then, a chamfered inner edge extraction method based on the shrinkage of an elliptical band and an adaptive weight optimal calculation based on redundant measurement data are presented to improve the measurement accuracy. Experiments are carried out to validate the presented method, and a high measurement accuracy with a standard deviation of 0.017 mm in the hole radius and 0.021 mm in hole spacing have eventually been achieved for the actual measurement workpieces, respectively. Compared with the common method, the measurement accuracy is improved by at least 77% and 53% in radius and spacing, respectively.

3D shape measurement in the presence of strong interreflections by using single-pixel imaging in a camera-projector system

Optical 3D shape measurements, such as fringe projection profilometry (FPP), are popular methods for recovering the surfaces of an object. However, traditional FPP cannot be applied to measure regions that contain strong interreflections, resulting in failure in 3D shape measurement. In this study, a method based on single-pixel imaging (SI) is proposed to measure 3D shapes in the presence of interreflections. SI is utilized to separate direct illumination from indirect illumination. Then, the corresponding points between the pixels of a camera and a projector can be obtained through the direct illumination. The 3D shapes of regions with strong interreflections can be reconstructed with the obtained corresponding points based on triangulation. Experimental results demonstrate that the proposed method can be used to separate direct and indirect illumination and measure 3D objects with interreflections.

High-Accuracy 3-D Sensor for Rivet Inspection Using Fringe Projection Profilometry with Texture Constraint

Riveted workpieces are widely used in manufacturing; however, current inspection sensors are mainly limited in nondestructive testing and obtaining the high-accuracy dimension automatically is difficult. We developed a 3-D sensor for rivet inspection using fringe projection profilometry (FPP) with texture constraint. We used multi-intensity high dynamic range (HDR) FPP method to address the varying reflectance of the metal surface then utilized an additional constraint calculated from the fused HDR texture to compensate for the artifacts caused by phase mixture around the stepwise edge. By combining the 2-D contours and 3-D FPP data, rivets can be easily segmented, and the edge points can be further refined for diameter measurement. We tested the performance on a sample of riveted aluminum frame and evaluated the accuracy using standard objects. Experiments show that denser 3-D data of a riveted metal workpiece can be acquired with high accuracy. Compared with the traditional FPP method, the diameter measurement accuracy can be improved by 50%.

Fixed window aggregation AD-census algorithm for phase-based stereo matching

Phase-based stereo matching (PSM) is a vital step in binocular structured light. PSM is hard to strike a balance between efficiency and accuracy, especially because of the absolute phase matrix's (APM) double data type. It means that PSM needs more run time and memory than conventional intensity images' stereo matching. In this paper, we propose a modified absolute difference (AD)-Census algorithm called the fixed window aggregation AD-Census (FWA-AD-Census) to balance the contradiction between efficiency and accuracy in PSM. The FWA-AD-Census aggregates matching cost in a fixed support window instead of an adaptive support window in AD-Census. We analyze the reason why PSM is more suitable to aggregate the matching cost in a fixed support window. Simulations and experiments are conducted to verify the FWA-AD-Census's performances by comparing the FWA-AD-Census with two other local stereo matching algorithms. One is the AD-Census, which is more accurate but less efficient. Its matching cost is aggregated in an adaptive support window. Another is the sum of absolute difference (SAD), which is more efficient but less accurate, and its matching cost is aggregated in a fixed support window. Theoretical analysis and experimental results both indicate that the proposed algorithm can achieve similar accuracy to the AD-Census with less run time.

Reference-plane-based fast pixel-by-pixel absolute phase retrieval for height measurement

Absolute phase retrieval is essential for height measurement in digital fringe projection. However, projections of additional structured patterns that are normally required for phase unwrapping increase the measurement complexity. In this paper, we propose two reference-plane-based pixel-by-pixel absolute phase retrieval techniques with as few projections as possible, suitable for different object depth ranges. The wrapped phase on the object is absolutely unwrapped by referring just to the absolute phase map on the reference plane. Single-frequency absolute phase retrieval with one-reference-plane-based calibration is first proposed for objects within a height limit that equals a calibrated system constant. To extend the measurement depth range, dual-frequency absolute phase retrieval with two parallel reference planes is further proposed. The additional low frequency is used to choose the unwrapping reference from the two reference plane phases for unwrapping the high-frequency phase. Moreover, the proposed techniques are capable of high-frequency absolute phase unwrapping for objects with step-height surface discontinuities. Experiments have been conducted to demonstrate the efficiency of the proposed two techniques.