CN107941147B - Non-contact online measurement method for three-dimensional coordinates of large-scale system - Google Patents
Non-contact online measurement method for three-dimensional coordinates of large-scale system Download PDFInfo
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- CN107941147B CN107941147B CN201711143078.9A CN201711143078A CN107941147B CN 107941147 B CN107941147 B CN 107941147B CN 201711143078 A CN201711143078 A CN 201711143078A CN 107941147 B CN107941147 B CN 107941147B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/002—Measuring arrangements characterised by the use of optical techniques for measuring two or more coordinates
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/2518—Projection by scanning of the object
- G01B11/2527—Projection by scanning of the object with phase change by in-plane movement of the patern
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/254—Projection of a pattern, viewing through a pattern, e.g. moiré
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/2545—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object with one projection direction and several detection directions, e.g. stereo
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Abstract
The invention provides a non-contact online measuring method for three-dimensional coordinates of a large-scale system, wherein the used measuring device comprises a camera, a laser displacement sensor, a projector and a control system; the camera, the laser displacement sensor and the projector are respectively connected with the control system through cables, the laser displacement sensor is used for scanning the dead angle of the measured object with high precision, and the laser displacement sensor transmits the scanned image to the control system. The invention adopts monocular visual information, structured light and laser displacement detection data fusion, can measure the three-dimensional size with high precision, and can be used for state monitoring and quality inspection during the processing of key parts with large-scale complex curved surfaces and complex structures.
Description
Technical Field
The invention relates to the field of three-dimensional size measurement, in particular to a three-dimensional coordinate non-contact online measurement method for a large-scale system.
Background
In the military and national defense fields of aerospace, missiles, heavy weaponry and the like, along with the higher and higher requirements on the performance of a large-scale system, the processing and manufacturing of key parts of large-scale complex curved surfaces and complex structures and the three-dimensional measurement for monitoring the state and the performance of large-scale components are challenged and opportunistic before. In the fields of automobile and ship manufacturing, the output and sales volume of China is always at the front of the world in recent years, however, corresponding to the strong market demand and the output and sales volume, the domestic large ship propeller has serious defects in manufacturing capability and low autonomous ship loading rate; automobile precision molds and high-performance engines mainly depend on imports, and the independent development of equipment manufacturing industry and basic industry in China is severely restricted. The fundamental reasons for these problems are that the three-dimensional measurement level of the key components of large complex curved surfaces and complex structures is relatively lagged, which results in low manufacturing efficiency, difficult guarantee of processing precision, and the like.
The measurement technology which is an important support of modern manufacturing industry is not only used as a final product quality assessment means, but also more importantly used for providing complete information feedback for the product design and quality monitoring service in the manufacturing process. The measurement mode is also added into the processing and manufacturing process from the traditional off-line measurement, so as to realize the on-line measurement. Compared with offline measurement, online measurement has great advantages: the workpiece is measured on the processing site in an online measurement mode, a measuring clamp does not need to be additionally manufactured, and an object does not need to be transferred to a measuring chamber, so that the economic and time consumption can be reduced; the online measurement advances the measurement process to the processing process, integrates the quality control into the manufacturing process, changes the quality detection after processing into real-time detection in the processing, can find the quality problem at any time and adjust the process in time, improves the yield of the product; the problems in the manufacturing process can be found in time through online measurement, and the problems are corrected in time through measures such as adjustment of processing technological parameters, introduction of error compensation and the like, so that agile processing is realized, and the processing quality is guaranteed. Therefore, how to measure the three-dimensional size of the key parts of large-scale complex curved surfaces and complex structures on line becomes an important subject in the military and equipment manufacturing fields of aerospace, missiles, weaponry and equipment, automobiles, shipbuilding and the like.
Disclosure of Invention
The invention aims to provide a non-contact online measurement method for three-dimensional coordinates of a large-scale system, which solves the problem of large errors in online measurement of three-dimensional sizes of parts with large-scale complex curved surfaces and complex structures.
The method comprises the steps of carrying out high-precision scanning on the dead angle of a measured object by using a laser displacement sensor, and transmitting an image obtained by scanning to a control system by using the laser displacement sensor.
The laser displacement sensor has higher measurement precision, can realize high-precision measurement when being used for measuring shapes, and has lower cost.
Further, the method comprises the steps of:
firstly, calibrating a camera;
secondly, projecting the periodically modulated fringe pattern onto an object to be measured by a projector;
thirdly, shooting a fringe pattern on the measured object by the camera;
fourthly, processing the image shot by the camera by the control system;
step five, the laser displacement sensor carries out high-precision scanning;
and step six, controlling the system to reconstruct the three-dimensional image.
The method can realize non-contact on-line measurement of a large-scale system, has the characteristic of high measurement precision, and can be used for state monitoring and quality inspection during processing of key parts with large-scale complex curved surfaces and complex structures.
Further, the device used in the measurement process comprises a camera, a laser displacement sensor, a projector and a control system;
the camera, the laser displacement sensor and the projector are respectively connected with the control system through cables;
the projector projects the sent periodic modulation fringe pattern to the surface of the large-scale system to be measured according to a control instruction of the control system;
the camera shoots the fringe patterns on a plurality of parts of the object to be tested and transmits the shot images to the control system;
the laser displacement sensor scans the dead angle of the measured object with high precision and transmits the scanned image to a control system;
the control system firstly processes according to the stripe pattern and the shot image to obtain a basic three-dimensional topography of the system to be measured; and combining the scanned image of the laser displacement sensor to obtain the final three-dimensional size and image of the system to be measured.
The projector projects stripes, the camera is matched with the laser displacement sensor to shoot a measured object, a high-precision and clear picture is obtained, and the picture is further processed by the control system.
Further, the first step comprises calibrating the camera parameters by adopting a 2D plane template calibration method; and calibrating the phase position-height of the camera by adopting a standard plane translation method.
The camera calibration is used for improving the precision of the camera and improving the definition and the precision of imaging.
Further, the camera parameters include a focal length f, a pixel interval Δ x in the horizontal direction of the image plane, a pixel interval Δ y in the vertical direction of the image plane, and a principal point coordinate (u)0，v0)。
The calibration of the camera parameters plays an important role in the camera shooting performance of the camera.
Further, the phase-height mapping relationship is:
wherein
For phase, h is height, and a and b are constants.
The camera after the calibration of the phase-height mapping relation has high shooting precision, and the online measurement precision of the system can be improved.
Further, the fringe pattern of the periodic modulation is a sinusoidal fringe pattern.
The periodically modulated stripes have stability and certain regularity, and when the periodically modulated stripes are projected onto an object to be changed, the actual graph of the object can be obtained according to the deformation and the existing imaging rule.
And further, the step four comprises the step of extracting the phase by the control system by using a four-step phase shifting method and performing unwrapping processing on the phase by using a phase unwrapping algorithm.
And the control system performs fusion processing on the graphs to obtain three-dimensional data of the object.
The invention has the beneficial effects that:
(1) monocular visual information, structured light and laser displacement detection data are fused, so that the three-dimensional size can be measured with high precision;
(2) the device can be used for monitoring the state and inspecting the quality of key parts with large-scale complex curved surfaces and complex structures during processing;
(3) the laser displacement sensor is adopted for scanning, has higher measurement precision, can realize high-precision measurement when being used for measuring shapes, and has lower cost.
Drawings
The drawings are only for purposes of illustrating particular embodiments and are not to be construed as limiting the invention, wherein like reference numerals are used to designate like parts throughout.
FIG. 1 is a schematic diagram of the overall structure of the on-line measuring device of the present invention;
FIG. 2 is a flow chart of an on-line measurement method of the present invention;
FIG. 3 is an image taken by a camera in an embodiment of the invention;
FIG. 4 is a graph obtained after image unwrapping processing in an embodiment of the present invention;
fig. 5 is a graph obtained by three-dimensional reconstruction in an embodiment of the present invention.
In the figure: 1-projector, 2-image camera, 3-control system, 4-laser displacement sensor.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
For the floor area more than 25m2The invention provides a three-dimensional coordinate non-contact on-line measuring method, as shown in fig. 1, the device used in the implementation process of the method comprises a camera, a laser displacement sensor, a projector, a control system and the like.
The camera, the laser displacement sensor and the projector are respectively connected with the control system through cables.
The projector projects the sent periodic modulation fringe pattern to the surface of the large-scale system to be measured according to a control instruction of the control system;
the camera shoots the fringe patterns on a plurality of parts of the object to be tested and transmits the shot images to the control system;
the laser displacement sensor scans the dead angle of the measured object with high precision and transmits the scanned image to a control system;
the control system firstly processes according to the stripe pattern and the shot image to obtain a basic three-dimensional topography of the system to be measured; and combining the scanned image of the laser displacement sensor to obtain the final three-dimensional size and image of the system to be measured.
Specifically, the three-dimensional coordinate non-contact online measurement method for the large-scale system, as shown in fig. 2, includes the following steps:
step one, calibrating a camera
And a video camera and a projector are installed, the relative position and the optical axis included angle of the video camera and the projector are adjusted, and the tested equipment is ensured to be in the projection range of the projector. Calibrating the parameters of the camera by adopting a 2D plane template calibration method; and obtaining a phase-height mapping relation of the camera by adopting a standard plane translation method, and realizing phase-height calibration.
In order to ensure that the tested equipment is in the projection range of the projectors, the installation number of the projectors is n, all the projectors are installed on a spherical surface with the center of the equipment as a sphere and the radius of R and are uniformly distributed, when n (R multiplied by α) is larger than or equal to 2S, the tested equipment can be considered to be in the projection range of the projectors, wherein S is the surface area of the equipment, and α is the projection angle of the projectors.
The camera parameters comprise focal length f, pixel interval delta x in the horizontal direction of an image plane, pixel interval delta y in the vertical direction of the image plane, and projection position coordinates of the optical center of the camera on a CCD imaging plane, namely principal point coordinates (u)0，v0). Because the relationship between the three-dimensional geometric position of a point on the surface of the object to be measured and the point in the image coordinate system is determined by the position of the camera in space and the camera parameters, when the three-dimensional geometric position of each point of the object is required to be accurately calculated, firstly, the camera parameters are calibratedAnd (4) counting.
The phase-height mapping relationship is:
wherein
For phase, h is height, and a and b are constants.
Step two, projecting by a projector
In the conventional phase shift method, the measurement system needs a relatively complex phase shift device to control and generate a precise fixed-step phase shift, which is relatively complex. In the method, a control system is used for compiling and generating a fringe pattern with periodic modulation for projection, and the fringe pattern is projected onto an object to be measured through a projector. The control system sends out a projection instruction, a single projector is used for projecting the periodically modulated fringe pattern to the surface part curved surface of the measured object, and the phase of the grating fringe of each point is shifted due to the change of the height of the surface part curved surface of the object.
Step three, shooting by the camera
The camera rapidly shoots the fringe images on a plurality of parts of the measured object to obtain a plurality of fringe images containing phase differences, and the images contain the curved surface information of the measured part. The camera sends the shot picture information to the control system.
Step four, the control system processes the images shot by the camera
After all projectors are projected and photographed once, according to the photographed fringe pattern containing the information of the curved surface of the part to be measured, the control system extracts the phase by using a four-step phase shifting method, and then the phase is subjected to unwrapping processing by using a phase unwrapping algorithm.
And (2) according to the camera parameters and the phase-height mapping relation which are calibrated in advance in the step one, after the phase is obtained in actual measurement, recovering three-dimensional height point data of the object surface from the phase value according to the determined phase-height relation, and substituting the measured phase into the relation according to the phase-height mapping relation so as to calculate the height value. And finishing the measurement of the three-dimensional shape of the surface of the object and the basic three-dimensional reconstruction of the measured object, namely obtaining the three-dimensional image of each curved surface. The control system adopts a mark-free point splicing algorithm to splice reasonably advanced images of the three-dimensional images of the curved surfaces to obtain a basic three-dimensional topography map of the measured object.
Phase unwrapping algorithm: the four-step phase shift is used to obtain the pressed wrapping phase, and then the regional growth method is used for unwrapping.
The phase value obtained by the four-step phase shifting method is wrapped between the range [ -pi, pi ] of the arctangent function, and discontinuous phases of discontinuity and jump exist. The phase cannot directly reflect the real phase change, and the discontinuity and jump in the phase main value graph can be eliminated only by performing phase expansion on the phase change, so that continuously distributed phase true values are obtained. And (3) unpacking: and comparing the phase main values of two adjacent pixels along the row or the column of the phase matrix from the starting point of the phase value by adopting a region growing method, wherein for a continuously-changed object, the phase value is continuous, and therefore when the phase difference between two adjacent pixels exceeds a certain range, the phase value of the next pixel is added with (or subtracted by) the phase value of integral multiple of 2 pi to obtain the real phase.
A mark-point-free splicing algorithm: due to the limitation of the projection phase field and the shooting range of the camera, the point cloud splicing is carried out after multiple times of measurement, and the measurement can be finished. And (3) adopting an SIFT registration principle to assist in completing the automatic point cloud splicing work. Firstly, all scales and image positions are searched, and potential feature points which have invariance to scale scaling and rotation change can be effectively detected by using a Gaussian difference formula. Determining the position and scale of the key point, allocating each key point to a direction, converting all operations on the data of the image into the operations on the direction, the scale size and the position of the feature point, and generating the feature point descriptor by the gradient statistics of the area around the current scale of the key point.
Step five, the laser displacement sensor carries out high-precision scanning
In order to ensure that the measurement precision meets the requirement, according to the preliminarily obtained three-dimensional image information of the large-scale component and the three-dimensional information of each part of curved surface, aiming at information missing points, characteristic points, complex structure positions and the like in the preliminarily spliced image, a control system needs to supplement and perfect individual information in the preliminarily obtained three-dimensional image after splicing, specifically, the control system controls a laser displacement sensor to serve as an optical probe, high-precision scanning is carried out on the dead angle of a measured object based on a laser displacement detection technology, and the laser displacement sensor transmits the scanned image and displacement information to the control system.
Information missing points, characteristic points and complex structure positions in the image are identified by a method of detecting by using a Gaussian Laplacian operator.
Step six, the control system carries out three-dimensional image reconstruction
After a high-precision image and displacement information obtained by scanning of the laser displacement sensor are transmitted to the control system, the control system adds the data into an existing database, and then performs three-dimensional image reconstruction on the three-dimensional size of a key part with a large complex curved surface and a complex structure by using a Phase Measurement Profilometry (PMP) to obtain a three-dimensional coordinate of an object, namely the length, the width and the height of the object. And obtaining the three-dimensional size and the image meeting the precision requirement, and feeding back the information into a readable form of a CAM system, thereby realizing the non-contact on-line measurement of the three-dimensional size of the key part with a large complex curved surface and a complex structure.
In this embodiment, the three-dimensional coordinate non-contact on-line measurement of the spherical mirror system shown in the figure is specifically as follows:
step one, calibrating an image camera
Calibrating the camera parameters by adopting a 2D plane template calibration method to obtain the camera parameters: Δ x ═ Δ y ═ 4.65 μm, f ═ 35.17mm, (u)0，v0) The unit is a pixel (695.5, 519.5).
The standard plane translation method is adopted to obtain the phase-height mapping relation of which a is 0.3 and b is 0.025, namely
Step two, projecting by a projector
And the control system sends a projection instruction, and the projector is used for projecting the sinusoidal stripe image to the surface part curved surface of the measured object.
Step three, shooting by using a camera
Using a CCD camera as an image acquisition tool, as shown in fig. 3, a plurality of fringe images including phase differences are obtained by photographing fringe images on a plurality of portions of a measured object, and the CCD camera transmits the photographed image information to a control system.
Step four, the control system processes the images shot by the camera
According to the shot fringe pattern containing the information of the curved surface of the part to be detected, the control system extracts the phase by using a four-step phase shifting method, then the phase is subjected to unwrapping processing by using a phase unwrapping algorithm, and the graph obtained after unwrapping processing is shown in fig. 4.
Step five, the laser displacement sensor carries out high-precision scanning
And aiming at the missing points and the like in the three-dimensional image obtained by the primary splicing, the control system controls the laser displacement sensor to further scan the measured object, and transmits the scanned image to the control system.
Step six, the control system carries out three-dimensional image reconstruction
And the control system performs three-dimensional image reconstruction again according to the image scanned by the laser displacement sensor on the basis of the initial splicing of the three-dimensional image, and the reconstructed three-dimensional image is shown in fig. 5.
In conclusion, the invention provides a large-scale system three-dimensional coordinate non-contact online measurement method, which adopts monocular visual information, structured light and laser displacement detection data fusion, can measure three-dimensional dimensions with high precision, and can be used for state monitoring and quality inspection during processing of key parts with large-scale complex curved surfaces and complex structures.
Although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that various modifications are allowable without departing from the spirit and scope of the invention, which fall within the scope of the claims of the present invention.
Claims (3)
1. The large-scale system three-dimensional coordinate non-contact on-line measuring method is characterized by comprising the following steps:
firstly, calibrating a camera;
secondly, projecting the periodically modulated fringe pattern onto an object to be measured by a projector;
thirdly, shooting a fringe pattern on the measured object by the camera;
fourthly, processing the image shot by the camera by the control system;
step five, the laser displacement sensor carries out high-precision scanning;
step six, the control system carries out three-dimensional image reconstruction;
the method comprises the following steps of performing high-precision scanning on a dead angle of a measured object by using a laser displacement sensor, and transmitting an image obtained by scanning to a control system by using the laser displacement sensor;
the mounting number of the projectors is n, all the projectors are mounted on a spherical surface with the center of the equipment as a sphere and the radius of R, the projectors are uniformly distributed, and when n (R multiplied by α) is more than or equal to 2S, the equipment to be tested is in the projection range of the projectors, wherein S is the surface area of the equipment, and α is the projection angle of the projectors;
the first step comprises calibrating the parameters of the camera by adopting a 2D plane template calibration method; calibrating the phase position-height of the camera by adopting a standard plane translation method;
the camera parameters comprise a focal length f, a pixel interval delta x in the horizontal direction of an image plane, a pixel interval delta y in the vertical direction of the image plane and a principal point coordinate (u)0，v0)；
The phase-height mapping relation is as follows:
wherein
Is the phase, h is the height, a and b are constants;
the periodically modulated fringe pattern is a sinusoidal fringe pattern.
2. The on-line measuring method according to claim 1, wherein the devices used in the measuring process comprise a camera, a laser displacement sensor, a projector and a control system;
the camera, the laser displacement sensor and the projector are respectively connected with the control system through cables;
the projector projects the sent periodic modulation fringe pattern to the surface of the large-scale system to be measured according to a control instruction of the control system;
the camera shoots the fringe patterns on a plurality of parts of the object to be tested and transmits the shot images to the control system;
the laser displacement sensor scans the dead angle of the measured object with high precision and transmits the scanned image to a control system;
the control system firstly processes according to the stripe pattern and the shot image to obtain a basic three-dimensional topography of the system to be measured; and combining the scanned image of the laser displacement sensor to obtain the final three-dimensional size and image of the system to be measured.
3. The on-line measuring method of claim 1, wherein the fourth step comprises the control system extracting the phase by a four-step phase shifting method and unwrapping the phase by a phase unwrapping algorithm.
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