A novel three-dimensional shape measurement method based on a look-up table

Fringe projection profilometry is widely used for three-dimensional shape measurement. In an oblique-angle projection, the fringe cycle is broadened on the reference plane. Phase errors are mainly caused by the nonlinear gamma of the projector and fringe cycle broadening. This study describes a phase error compensation method to eliminate these phase errors. A look-up table that stores phase errors is constructed for phase error compensation. Based on it, a new height equation is proposed. The experimental results show that the proposed method can compensate for the phase errors of the fringe projection profilometry, thereby improving the measurement accuracy significantly.     

Pulse-width modulation in defocused three-dimensional fringe projection

Shape measurements by fringe projection methods require high-quality sinusoidal fringes. We present a sinusoidal fringe generation technique that utilizes slightly defocused binary fringe projection. The proposed method is a spatial version of the well-known pulse-width modulation (PWM) technique of electrical engineering. PWM is easy to implement using off-the-shelf projectors, and it allows us to overcome the gamma problem (i.e., the nonlinear projector response) in the output light intensity. We will demonstrate that, with a small defocusing level--lower than with other techniques proposed in the literature--a high-quality sinusoidal pattern is obtained. Validation experiments using a commercial video projector are presented.     

基于二进制条纹加相位编码条纹离焦投影的三维测量方法

复杂表面的精密三维测量在工业无损检测中非常重要。二进制条纹离焦投影方法在快速三维测量中有重要的应用前景,但该方法难以实现复杂表面高精度三维测量。为此,提出了基于二进制条纹加相位编码条纹离焦投影的三维测量方法。由于离焦投影滤除了高次谐波和高频噪声,可以克服投影仪的非线性伽马效应,与传统投影正弦条纹方法相比,提高了其测量精度。针对离焦投影时,随着相位编码条纹频率增大,条纹级次判决困难,出现周期错位,导致相位解包裹出错,提出了相移编码方法来解决以上问题。采用相移编码方法校正周期错位,使条纹级次判决准确,进一步提高其测量精度。实验结果表明,其测量精度可以达到0.044 mm,验证了本方法的有效性和实用性。     

Complex surface three-dimensional shape measurement method based on defocused Gray code plus phase-shifting

Binary pattern defocused projection method can overcome the nonlinear gamma of the projector, as well as filter high harmonics and high-frequency noise. However, high-accuracy three-dimensional (3-D) shape measurement of complex surface using it still remains a challenge. Therefore, a novel Gray code plus phase-shifting method based on defocusing is proposed to solve the problem. The edges of Gray code patterns become blurred owing to defocus, which makes the recovery of accurate Gray code patterns difficult. To solve this problem, the positive and inverse Gray code patterns are projected to obtain threshold values, which are used to achieve the binarization of Gray code patterns. This method is robust and suitable for different defocus levels. Compared with the traditional Gray code plus phase-shifting method, the experimental results prove the effectiveness and feasibility of the proposed method.     

Calibration method for fringe projection profilometry with a binary defocusing technique

A novel and simple calibration method for fringe projection profilometry with a binary defocusing technique is proposed and verified by experiments. This paper theoretically presents the principle that the one-to-one mapping servers as spatially invariant to environment in the phase domain when the projector is defocused. In terms of this principle, only two reference planes are introduced in the volume of projector defocusing (the measured volume) to specify one constraint, i.e., the emitted light beams, which are determined by the sub-pixel homologous pairs from the measured object to the reference planes in the phase domain. The nonlinear camera model is utilized to define the other constraint, i.e., the reflected light beams. Then, combining these two constraints will calibrate the 3D information of the measured object. It is pointed out that the proposed method does not require the calibration of the projector. Experiments demonstrate the performance of our proposed approach: the measurement accuracy can reach about 0.0916 mm with the binary defocusing technique.     

Shifted-phase calibration for a 3-D shape measurement system based on orthogonal composite grating projection

This paper proposes a novel method for reducing measurement error caused by spectrum overlapping in orthogonal-composite-grating-based 3-D measurement method. For 3-D measurement systems based on orthogonal composite grating projection, spectrum overlapping causes phase of each deformed phase-shifting fringe changed differently, which violates the principle that the shifted phases between adjacent deformed fringes must be equivalent to 2π/3, and therefore results in phase measurement error. The proposed shifted-phase calibration method is based on that phase variation of each deformed fringe is independent of height and reflectivity of the measured object. Three composite gratings are projected on the reference plane, and each carrier channel includes three phase-shifting gratings needed in phase measuring profilometry (PMP). Because the adjacent phase-shifting fringes demodulated from the same carrier channel have the phase difference of 2π/3, we can respectively calculate the reference plane's phases of three carrier channels by the phase algorithm of PMP method, and the shifted phases between them are obtained. When an object is measured, the shifted phases between deformed phase-shifting fringes can be calibrated. A new 3-D measurement mathematical model is set to reconstruct object. Our experiments prove that the proposed method can effectively restrain the effect of spectrum overlapping and improve measurement accuracy almost one times.     

一种基于参数标定的投影条纹周期简易校正方法

基于三角测量原理的条纹投影轮廓测量系统中,倾斜投影到参考平面上的条纹将产生周期展宽现象,引起相位失真甚至影响测量精度.论文以条纹位置为控制变量推导出条纹周期校正的线性数学模型,通过简便的标定获得模型参数,由此反算出新的待投影条纹,并在参考平面上获得周期分布的投影条纹.实验结果表明校正后的条纹周期变化范围在±0.1像素内...     

3D shape measurement of larger complex objects based on fringe cycle correction

The grating fringe on the reference plane is broadened in the intersecting axis system because of oblique-angle projection. In order to solve this problem, we study the theoretical model of the temporal phase unwrapping method based on the fringe cycle correction. We also study the 3D shape measurement theoretical model of the larger complex objects after considering the coordinate deviation and lens distortion. Experimental results demonstrate that the fringe cycle on the reference plane can be corrected to a constant value, the lens distortion can be corrected, and 3D shape of larger complex objects can be accurately measured.     

3-D shape measurement based on complementary Gray-code light

A combination of phase-shift with Gray-code light projection into a three-dimensional (3-D) measurement system has been exploited to digitalize 3-D shape information of a tested object, even with a discontinuous surface. Unfortunately, the phase unwrapping will fall into an error, when an improper value of Gray coding is caused by mistake at the partial boundary of two adjacent binary words. To this end, a new complementary Gray-code method is proposed in this paper as well as the corresponding phase-unwrapping method. This problem of phase unwrapping could be cleverly solved by projecting an additional Gray-code pattern to extend this code and using the different and complementary boundary locations of the traditional and additional codes. The results of computer simulation and experiment confirm that this proposed method based on complementary Gray-code can reliably reconstruct the nature phase distribution of the tested object with only one extra fringe pattern.     

Least-squares calibration method for fringe projection profilometry with some practical considerations

Fringe projection profilometry (FPP) is a widely used three-dimensional profile measurement technique. One vital step in this technique is calibration, which determines the system accuracy. The least-squares method, because of its flexibility and simplicity, is commonly used in system calibration for FPP. However, calibration results are affected by the nonlinear gamma of the projector and projection fringe cycle broadening. This paper proposes a new look-up table (LUT) generation method by analyzing the differences between the real and ideal unwrapped phases. The aforementioned problems could then be solved after the phase error is compensated by the LUT. Finally, the validity of the proposed method is demonstrated through experiments, and the accuracy reaches 0.02 mm.     

A study on the 3-D measurement by using digital projection moiré method

Moiré topography method is a well-known non-contacting 3-D measurement method. Recently, the automatic 3-D measurement technique by moiré topography has been developed in order to apply to the engineering and medical fields. The projection moiré topography is very attractive because of its high measuring speed and high sensitivity. In this paper, using the two-wavelength methods of projection moiré topography was investigated to measure the 3-D shape of an object with 2π-ambiguity problems. Rapid measurement can be accomplished by the synchronization between CCD camera and projector. The experimental results prove that the proposed scheme is capable of finding absolute fringe orders, so that the 2π-ambiguity problems can be effectively overcome so as to treat large step discontinuities in measured objects.     

复杂刚性运动物体的高精度三维测量算法

基于相移法的三维形貌重建精度高,对环境噪声和阴影等不敏感,但由于多幅条纹解相位,难以应用于动态物体的三维测量中,为此,提出了一种新的算法.基于Harris算法提取刚性运动棋盘格的角点,确定相邻两帧采集条纹图像之间的像素偏差并校正采集条纹图像;根据投影仪和摄像机的标定参数建立投影图像和采集图像之间的空间变换矩阵,并根据变...     

3-D object profilometry based on direct fringe displacement analysis

A simple, fast and accurate method for 3-D object profilometry is proposed and verified by simulation and experiment. The profilometry method is based on the principle that the height data of a measured object can be obtained from the relevant fringe displacement, which in turn can be obtained by determining the precise position of the fringe center on the reference plane and on the object's surface. With the aid of a fringe skeleton extraction technique, the 3-D information can be acquired even from those images in which some fringes are squeezed, interrupted or shadowed.     

High-quality binary fringe generation via joint optimization on intensity and phase

There have been active studies on optimized dithering techniques to improve 3D shape measurement quality with defocused projectors. These techniques optimize the fringe quality in either phase domain or intensity domain according to their objective functions. Phase based optimization is direct and effective, but is sensitive to projector defocus levels. Intensity based optimization is robust to projector defocus levels, but it does not fully improve the phase quality. This paper presents a joint optimization technique to combine the merits of both the intensity and phase based optimization, which includes a pre-intensity optimization and a further optimization based on the synthesized error function. Then this technique is implemented in two frameworks, the whole-fringe optimization and the best-patch optimization, to generate binary fringe patterns. Both simulations and experiments show that the proposed technique can generate binary fringe patterns with high phase quality and robustness to projector defocus levels.     

Testing micro devices with fringe projection and white-light interferometry

Optical sensors are very suitable for the analysis of microscopic structures and micro devices. We compare two very promising methods: the white-light interferometry and the fringe projection technique for the application to this task. The fringe projection is very useful for fast measurement of objects with vertical dimensions of some μm. White-light interferometry is especially useful for highly resolved 3-D measurements. Furthermore, we present a new technique, the scanning fringe projection (SFP), which enables absolute 3-D measurements with one single grating period.     

Application of robust color composite fringe in flip-chip solder bump 3-D measurement

This study developed a 3-D measurement system based on flip-chip solder bump, used fringes with different modulation intensities in color channels, in order to produce color composite fringe with robustness, and proposed a multi-channel composite phase unwrapping algorithm, which uses fringe modulation weights of different channels to recombine the phase information for better measurement accuracy and stability. The experimental results showed that the average measurement accuracy is 0.43μm and the standard deviation is 1.38 µm. The results thus proved that the proposed 3-D measurement system is effective in measuring a plane with a height of 50 μm. In the flip-chip solder bump measuring experiment, different fringe modulation configurations were tested to overcome the problem of reflective coefficient between the flip-chip base board and the solder bump. The proposed system has a good measurement results and robust stability in the solder bump measurement, and can be used for the measurement of 3-D information for micron flip-chip solder bump application.     

基于自适应条纹投影的高反光物体三维面形测量

结构光投影方法在三维形貌测量中应用广泛,但是由于被测物体表面反射率变化范围较大,过度曝光会导致相位信息无法获取。而传统的高动态范围扫描技术步骤复杂,耗时较长。文中提出一种自适应条纹投影技术,向待测物体表面投射较高灰度级的条纹图,判断并标记过度曝光点。降低投射强度后通过非线性最小二乘法拟合来确定每个饱和像素点最适合的最大输入灰度,用重新生成的自适应条纹图来采集图像并进行相位计算和三维形貌恢复。通过实验验证,该方法可以对物体表面的高反光区域进行有效测量,避免过度饱和,仿真误差在0.02 mm范围内,实测误差约为0.14 mm,实际实验对过曝点的补偿率可达到99%。     

基于声光栅的变频条纹投射系统

针对三维形貌测量中结构光照明系统投影速度慢、结构复杂、在线集成困难的问题,提出了一种基于声光栅的变频条纹投射系统。该系统利用拍频信号驱动声光偏转器,在声光晶体中形成两个重叠的光栅,光源发出的激光以布拉格角入射,形成两束一级衍射光,经透镜聚焦形成光强按正弦规律分布的结构光条纹。建立了数学模型,同时提出了一种新的相位凝固技术,使条纹空间频率和相位的变化规律得到了很好的解释。该系统结构紧凑、体积小,全电控可调,无任何机械移动部件,具有条纹投影速度快、精度高、动态可编程的特点。应用该系统对石膏像形貌进行测量,获得了用于三维成像的相位图。该投射系统对于解决复杂几何形状物体的三维测量问题具有较高的工程应用价值。     

Fringe projection profilometry based on complementary color-encoded fringe patterns

3D measurement techniques based on color-encoded fringe pattern projection have been widely used in various fields of engineering recently. There is one problem that the surface color of measured object may interfere with the color of projected fringe pattern. To solve this problem, a novel method based on complementary color-encoded fringe projection is proposed. Two color-encoded fringe patterns whose fringe colors are complementary are designed. The first pattern is with the sinusoidal fringe embedding into the green color channel which is used to evaluate phases by Fourier transform method. The fringe color of the captured image is established with the help of the complementary color fringe pattern, which is based on the feature of color complementation. Thus, the influence brought by the color of object surface can be eliminated, and decoding errors can be further reduced. Experiment results indicate that the proposed method is valid and can be applied to the measured colorful objects.     

基于正弦和三角波条纹投影的三维测量方法

在现有的针对复杂物体表面形貌的三维测量方法中, 为了完成绝对相位的测量, 通常需要处理至少6幅条纹图像, 限制了测量速度。提出了采用2幅正弦条纹和2幅三角波条纹图来获得物体三维形貌的方法。利用两步相移正弦条纹和两步相移三角条纹得到截断相位, 再利用两步相移三角波条纹得到条纹级次, 减少了投影条纹幅数, 提高测量速度。在得到条纹级次时, 计算三角波条纹强度调制和强度对比度, 与计算相位相比, 可以减少数据处理的时间, 进一步提高测量速度, 同时能减小物体表面反射率的影响, 提高了测量精度。测量最大高度为39 mm的阶梯状标准块, 得到的最大绝对误差和最大的RMS误差分别为0.045 mm和0.041 mm。验证了该方法的有效性和实用性, 在高速实时的复杂形貌三维测量中有广泛的应用前景。