CN108844459B - Calibration method and device of blade digital sample plate detection system - Google Patents
Calibration method and device of blade digital sample plate detection system Download PDFInfo
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- CN108844459B CN108844459B CN201810418349.5A CN201810418349A CN108844459B CN 108844459 B CN108844459 B CN 108844459B CN 201810418349 A CN201810418349 A CN 201810418349A CN 108844459 B CN108844459 B CN 108844459B
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- 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
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- G—PHYSICS
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
- G01B21/04—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness by measuring coordinates of points
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Abstract
The invention relates to the technical field of visual measurement, and particularly discloses a calibration method of a blade digital sample plate detection system, wherein the calibration method comprises the following steps: calibrating cameras for the first visual sensor and the second visual sensor respectively; respectively calibrating laser knife planes of the two vision sensors; respectively calibrating the motion directions of the two visual sensors according to the camera parameters and the measurement parameters; respectively converting the camera parameters of the second vision sensor into a measurement coordinate system; calibrating the position relation of the two vision sensors; converting the measurement parameters under the measurement coordinate system of the second vision sensor into the measurement coordinate system of the first vision sensor; calibrating a system coordinate system; and converting the measurement coordinate system under the first vision sensor into the system coordinate system. The invention also discloses a calibration device of the blade digital sample plate detection system. The calibration method of the blade digital sample plate detection system provided by the invention provides a complete calibration method.
Description
Technical Field
The invention relates to the technical field of vision measurement, in particular to a calibration method of a blade digital template detection system and a calibration device of the blade digital template detection system.
Background
The gas turbine is widely applied to the fields of aviation, aerospace, energy sources and the like, and as a core part in the gas turbine, the turbine blade has the characteristics of complex structure, high manufacturing process requirement, multiple measurement parameters and the like, and the shape error of the turbine blade affects the energy conversion efficiency of the whole gas turbine, so that the requirement on the accuracy and effectiveness of the measurement of the irregular molded surface is provided. The calibration modes of different blade measurement methods directly determine the whole measurement precision, and reflect the applicability, economy and high efficiency of the measurement method. In order to be suitable for the blade measurement characteristics of a blade digital sample plate detection device which can rapidly scan the blade profile, obtain complete point cloud of the blade, automatically analyze measurement parameters and output a detection report, an accurate, convenient, rapid and simple system calibration method needs to be established for the blade digital sample plate detection device.
The noncontact measurement method mainly uses a method of optical visual inspection. The laser plane needs to be calibrated by using the laser triangulation principle. The pottery and other uses a three-dimensional target consisting of 2 completely vertical planes to calibrate the camera parameters and the optical plane parameters of the measuring system at the same time, but needs to make a special calibration target. In addition, a binocular vision system shoots a laser picture, stereo correction is carried out on a double-camera image by using a stereo vision method, the center of a laser stripe is obtained, the correspondence between the center of the stripe and a camera is matched, laser plane parameters can also be calibrated, but two cameras are not suitable for a blade digital sample plate detection device. Errors necessarily exist in the installation of the monocular laser vision sensor and the movement mechanism, and the relation between a measurement coordinate system and the actual movement direction needs to be calibrated. The method has the advantages that the method obtains the motion direction information of the visual sensor by manufacturing the calibration object with a special shape, reconstructing the special calibration object through scanning and extracting the information of the characteristic points in the three-dimensional space, and has the defects of complex calibration process, high manufacturing precision of the calibration object and high cost. In the blade detection mechanism with the rotary table, the rotation center calibration result of the rotary table influences the coordinate conversion result of the blade profile measuring point. The method for calibrating the rotation center of the rotary table has a three-point method. The measuring equipment is required to be a combined measuring head of an optical measuring head and a contact measuring head. A calibration ball is placed at a certain position of a rotary table by a three-point method, the fixing of a Z axis of a measuring head is guaranteed, three points on a standard ball are measured in an xy plane and arranged in an isosceles triangle, the three points are used for calculating the center coordinates of the cross section of the ball at the position, then the rotary table is rotated, the relative motion between the standard ball and the rotary table is kept, and the centers of the cross sections at the three positions are sequentially calculated to solve the rotary center of the rotary table. According to the method, the coordinates of three points on the standard ball in an xy plane need to be known, the circle centers of the sections of the standard ball at 3 positions are obtained only by rotating for 2 times, and the calibration precision is not high.
In summary, the existing calibration methods for the laser plane, the movement direction and the rotation center have the following defects: (1) low calibration efficiency (2) low calibration accuracy (3) complicated calibration process (4) need to make calibration blocks (5) of specific shapes, and no systematic complete calibration method exists for a device adopting non-contact blade measurement.
Therefore, how to provide a complete calibration method becomes a technical problem to be solved urgently by those skilled in the art.
Disclosure of Invention
The present invention is directed to at least solve one of the technical problems in the prior art, and provides a calibration method and a calibration apparatus for a blade digital template detection system, so as to solve the problems in the prior art.
As a first aspect of the present invention, there is provided a calibration method for a blade digital template detection system, wherein the blade digital template detection system includes a first visual sensor and a second visual sensor, the first visual sensor and the second visual sensor are symmetrically disposed opposite to each other, and the calibration method for the blade digital template detection system includes:
calibrating cameras of the first visual sensor and the second visual sensor respectively to obtain camera parameters under a camera coordinate system;
respectively calibrating the laser knife plane of the first vision sensor and the second vision sensor to obtain measurement parameters under a measurement coordinate system;
respectively calibrating the motion directions of the first visual sensor and the second visual sensor according to the camera parameters and the measurement parameters to respectively obtain the offset of the Y axis of the measurement coordinate system of the first visual sensor and the second visual sensor and the actual motion direction;
converting the camera parameters of the first vision sensor and the second vision sensor from the camera coordinate system to the measurement coordinate system respectively into measurement parameters in the measurement coordinate system;
calibrating the position relation of the first visual sensor and the second visual sensor;
converting the measurement parameters of the second vision sensor under the measurement coordinate system to the measurement coordinate system of the first vision sensor;
calibrating a system coordinate system of the blade digital sample plate detection system;
and converting the measurement coordinate system under the first vision sensor into a system coordinate system of the blade digital template detection system to obtain complete parameters under the system coordinate system of the blade digital template detection system.
Preferably, the obtaining of the measurement parameters in the measurement coordinate system by respectively calibrating the laser knife plane for the first vision sensor and the second vision sensor includes:
shooting a plurality of groups of calibration plate images without laser stripes and with laser stripes by a camera calibrated by the camera;
acquiring the pose of a calibration plate under the camera coordinate system;
extracting the light strip center of the image with the laser strip;
calculating the physical coordinate value of the light bar center;
obtaining a laser light knife plane where the physical coordinate value of the center of the light bar is located by fitting to obtain a measurement coordinate system;
and outputting the measurement coordinate system and the transformation relation between the measurement coordinate system and the camera coordinate system.
Preferably, the acquiring the pose of the calibration board in the camera coordinate system includes:
and calculating the position poses of the n control points in the camera coordinate system according to the spatial position information of the n control points and the image point information of the n control points.
Preferably, the laser knife plane on which the physical coordinate values of the light bar centers are obtained by fitting includes:
and fitting the laser knife plane in which the physical coordinate value of the light bar center is located by a least square optimization method.
Preferably, the calibrating the motion directions of the first visual sensor and the second visual sensor according to the camera parameters and the measurement parameters, and obtaining the offsets of the Y axis of the measurement coordinate systems of the first visual sensor and the second visual sensor from the actual motion directions respectively includes:
moving the first vision sensor and the second vision sensor on a plurality of positions on a moving module respectively, and shooting a calibration plate at each position of movement;
acquiring the pose of a calibration plate;
calculating a relative pose transform for each location of the first vision sensor and a relative pose transform for each location of the second vision sensor, respectively;
solving a direction vector of the motion direction under a camera coordinate system;
and outputting the direction vector.
Preferably, the calibrating the position relationship between the first visual sensor and the second visual sensor comprises:
the first visual sensor and the second visual sensor scan a plurality of positions of a calibration ball in a measurement space simultaneously;
respectively three-dimensionally reconstructing and fitting the coordinates of the sphere centers of the calibration spheres at different positions;
and calculating the position relation between the first visual sensor and the second visual sensor by using the rigid body change.
Preferably, the system coordinate system calibration of the blade digital screed detecting system comprises:
placing a calibration ball at the edge of the turntable;
the spherical center coordinates of the calibration ball are fitted through scanning reconstruction of the first vision sensor;
keeping the calibration ball and the turntable relatively static, rotating the turntable, and repeating the scanning, reconstruction and fitting steps to obtain the coordinates of the center of the calibration ball at a plurality of positions;
and fitting a rotary shaft and a rotary center of the rotary table to obtain a system coordinate system and obtain a conversion relation between the measurement coordinate system and the system coordinate system.
Preferably, the first visual senseThe camera coordinate system of the device comprises Pc1(Xc1，Yc1，Zc1) The measurement coordinate system of the first vision sensor comprises Pl1(Xl1，Yl1，Zl1) The camera coordinate system of the second vision sensor comprises Pc2(Xc2，Yc2，Zc2) The measurement coordinate system of the second vision sensor comprises Pl2(Xl2，Yl2，Zl2)。
Preferably, the system coordinate system of the blade digital template detection system comprises Ps(Xs，Ys，Zs)。
As a second aspect of the present invention, there is provided a calibration apparatus for a blade digital template detection system, wherein the calibration apparatus for a blade digital template detection system comprises:
the camera calibration module is used for respectively calibrating the first visual sensor and the second visual sensor to obtain camera parameters under a camera coordinate system;
the laser optical knife plane calibration module is used for respectively carrying out laser optical knife plane calibration on the first vision sensor and the second vision sensor to obtain measurement parameters under a measurement coordinate system;
the motion direction calibration module is used for respectively calibrating the motion directions of the first visual sensor and the second visual sensor according to the camera parameters and the measurement parameters to respectively obtain the offset of the Y axis of the measurement coordinate system of the first visual sensor and the second visual sensor and the actual motion direction;
a first conversion module for converting the camera parameters of the first and second vision sensors from the camera coordinate system to the measurement coordinate system into measurement parameters in the measurement coordinate system, respectively;
the position relation calibration module is used for calibrating the position relation of the first visual sensor and the second visual sensor;
a second conversion module, configured to convert the measurement parameters in the measurement coordinate system of the second vision sensor into the measurement coordinate system of the first vision sensor;
the system coordinate system calibration module is used for calibrating a system coordinate system of the blade digital template detection system;
and the third conversion module is used for converting the measurement coordinate system under the first vision sensor into the system coordinate system of the blade digital template detection system to obtain the complete parameters under the system coordinate system of the blade digital template detection system.
The calibration method of the blade digital sample plate detection system provided by the invention is used for carrying out system calibration on the blade digital sample plate detection device which can rapidly scan the blade profile, acquire complete point cloud of the blade, automatically analyze measurement parameters and output a detection report. The device can be quickly calibrated by the universal calibration target, the camera calibration, the laser knife plane calibration, the measurement motion direction calibration, the equipment position relationship calibration and the system coordinate system calibration are completed, so that the interconversion relationship among the coordinate systems can be accurately obtained, the calibration cost is reduced, the complete calibration is realized, the calibration efficiency of the whole system can be improved, the system calibration process is simplified, and the applicability of the blade digital sample plate measuring device is realized.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a flowchart of a calibration method of a blade digital template detection system according to the present invention.
Fig. 2 is a schematic diagram of coordinate systems of a blade digital template detection system provided by the present invention.
FIG. 3 is a specific calibration flowchart of the calibration method of the blade digital template detection system according to the present invention.
Fig. 4 is a flow chart of laser knife plane calibration provided by the present invention.
Fig. 5 is a flow chart of the movement direction calibration provided by the present invention.
Fig. 6 is a flowchart of calibrating a position relationship between two vision sensors according to the present invention.
Fig. 7 is a flowchart of system coordinate system calibration provided by the present invention.
Fig. 8 is a schematic structural diagram of a calibration device of the blade digital template detection system provided by the invention.
Detailed Description
The following detailed description of embodiments of the invention refers to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the present invention, are given by way of illustration and explanation only, not limitation.
As a first aspect of the present invention, there is provided a calibration method for a blade digital template detection system, wherein the blade digital template detection system includes a first visual sensor and a second visual sensor, and the first visual sensor and the second visual sensor are symmetrically disposed opposite to each other, as shown in fig. 1, the calibration method for the blade digital template detection system includes:
s110, calibrating cameras of the first visual sensor and the second visual sensor respectively to obtain camera parameters under a camera coordinate system;
s120, respectively carrying out laser knife plane calibration on the first vision sensor and the second vision sensor to obtain measurement parameters under a measurement coordinate system;
s130, respectively calibrating the motion directions of the first visual sensor and the second visual sensor according to the camera parameters and the measurement parameters to respectively obtain the offset between the Y axis of the measurement coordinate system of the first visual sensor and the actual motion direction of the second visual sensor;
s140, converting the camera parameters of the first visual sensor and the second visual sensor from the camera coordinate system to the measurement coordinate system respectively to become measurement parameters in the measurement coordinate system;
s150, calibrating the position relation of the first visual sensor and the second visual sensor;
s160, converting the measurement parameters of the second vision sensor in the measurement coordinate system into the measurement coordinate system of the first vision sensor;
s170, calibrating a system coordinate system of the blade digital sample plate detection system;
and S180, converting the measurement coordinate system under the first vision sensor into a system coordinate system of the blade digital template detection system to obtain complete parameters under the system coordinate system of the blade digital template detection system.
The calibration method of the blade digital sample plate detection system provided by the invention is used for carrying out system calibration on the blade digital sample plate detection device which can rapidly scan the blade profile, acquire complete point cloud of the blade, automatically analyze measurement parameters and output a detection report. The device can be quickly calibrated by the universal calibration target, the camera calibration, the laser knife plane calibration, the measurement motion direction calibration, the equipment position relationship calibration and the system coordinate system calibration are completed, so that the interconversion relationship among the coordinate systems can be accurately obtained, the calibration cost is reduced, the complete calibration is realized, the calibration efficiency of the whole system can be improved, the system calibration process is simplified, and the applicability of the blade digital sample plate measuring device is realized.
The operation of the calibration method of the blade digital template detection system provided by the invention is described in detail below with reference to fig. 2 and 3.
FIG. 2 is a schematic diagram of the position and transformation of each coordinate system in the blade digital template detection device, Pc1(Xc1，Yc1，Zc1)、Pl1(Xl1，Yl1，Zl1) Is the camera coordinate system and the measurement coordinate system, P, of the first vision sensorc2(Xc2，Yc2，Zc2)、Pl2(Xl2，Yl2，Zl2) Camera coordinate system and measurement coordinate system, P, for the second vision sensors(Xs，Ys，Zs) Is a system coordinate system, [ R, T ]]relativeA transformation matrix [ R, T ] for calibrating the positional relationship between said first vision sensor and said second vision sensor]svstemA transformation matrix of the coordinate system and the system coordinate system is measured for the device. Extracting a laser stripe picture shot by a camera through a light stripe center, calibrating the motion direction to obtain the offset between the Y axis of a measurement coordinate system and the actual motion direction, converting the light stripe center from a camera coordinate system to a measurement coordinate system, and passing through [ R, T ]]relativeConverting the point cloud of light bars under the coordinate system measured by the second vision sensor to the coordinate system measured by the first vision sensor, and then using [ R, T ]]svstemAnd transforming the point cloud data measured after each rotation of the rotary table from the measurement coordinate system of the first vision sensor to the system coordinate system. The system calibration flow is shown in fig. 3, only one universal visual calibration plate is needed for camera calibration, laser knife plane calibration and measurement movement direction calibration, and only one universal calibration ball is needed for equipment position relation calibration and system coordinate system calibration. The calibration process is covered in calibration software which integrates functions of complete calibration process, calibration picture display, three-dimensional point cloud display, user interactive operation, point cloud fitting and the like. After calibration is completed, different vision sensors can directly obtain complete point clouds unified under a system coordinate system after scanning and reconstructing measured objects with different visual angles.
Specifically, the obtaining of the measurement parameters in the measurement coordinate system by respectively calibrating the laser knife plane of the first vision sensor and the second vision sensor includes:
shooting a plurality of groups of calibration plate images without laser stripes and with laser stripes by a camera calibrated by the camera;
acquiring the pose of a calibration plate under the camera coordinate system;
extracting the light strip center of the image with the laser strip;
calculating the physical coordinate value of the light bar center;
obtaining a laser light knife plane where the physical coordinate value of the center of the light bar is located by fitting to obtain a measurement coordinate system;
and outputting the measurement coordinate system and the transformation relation between the measurement coordinate system and the camera coordinate system.
The acquiring of the pose of the calibration plate under the camera coordinate system comprises:
and calculating the position poses of the n control points in the camera coordinate system according to the spatial position information of the n control points and the image point information of the n control points.
Further specifically, the laser knife plane where the physical coordinate values of the light bar centers are obtained by fitting includes:
and fitting the laser knife plane in which the physical coordinate value of the light bar center is located by a least square optimization method.
The laser knife plane calibration is described in detail below with reference to fig. 4.
And shooting a plurality of groups of calibration plate images without laser and with laser in a measurement space by using a calibrated camera, acquiring the pose of the calibration plate under a camera coordinate system by using a PnP (pseudo-random projection) method, and extracting the light strip center of the image with the laser stripes. The PnP method calculates the position and orientation of n control points in the camera coordinate system by knowing their spatial position information and their image point information. And solving the physical coordinate value of the light bar center according to the plane constraint provided By the calibration plate, and fitting the optical knife plane Ax + By + Cz + D where the physical coordinate of the light bar center is located By a least square optimization method to be 0. The measurement coordinate of the vision sensor is established on a laser knife plane, the vertical foot from the optical center of the camera to the laser knife plane is the origin of the measurement coordinate system, the direction parallel to the laser plane is the z axis, the direction parallel to the base line of the camera and the laser plane is the y axis, and the cross product of the two is the x axis, so that the optical knife plane coordinate system is obtained. A transformation matrix of physical dimensions from the image pixel coordinates of the laser stripe to actual physical coordinate values can be constructed in conjunction with the camera's internal reference matrix and the optical tool plane coordinate system.
Specifically, the calibrating the movement directions of the first visual sensor and the second visual sensor according to the camera parameters and the measurement parameters, and obtaining the offsets between the Y axis of the measurement coordinate system of the first visual sensor and the actual movement direction of the second visual sensor respectively includes:
moving the first vision sensor and the second vision sensor on a plurality of positions on a moving module respectively, and shooting a calibration plate at each position of movement;
acquiring the pose of a calibration plate;
calculating a relative pose transform for each location of the first vision sensor and a relative pose transform for each location of the second vision sensor, respectively;
solving a direction vector of the motion direction under a camera coordinate system;
and outputting the direction vector.
The direction of movement is specified in detail below with reference to fig. 5.
Because the visual sensor and the linear module of the blade digital sample plate detection device inevitably have errors in the installation process, the y axis of a measurement coordinate system cannot be ensured to be consistent with the actual movement direction, and the movement direction needs to be calibrated. The linear module carries a vision sensor to move a plurality of positions to shoot the calibration plate, the pose of the calibration plate is estimated by the PnP according to the corresponding information, the relative pose transformation of the vision sensor is calculated, and the direction vector of the motion direction under the camera measurement coordinate system is solved. If the vision sensor is installed obliquely according to the measurement requirement, the actual movement direction is still calibrated by using the method.
Specifically, the calibrating the position relationship between the first visual sensor and the second visual sensor includes:
the first visual sensor and the second visual sensor scan a plurality of positions of a calibration ball in a measurement space simultaneously;
respectively three-dimensionally reconstructing and fitting the coordinates of the sphere centers of the calibration spheres at different positions;
and calculating the position relation between the first visual sensor and the second visual sensor by using the rigid body change.
The calibration of the positional relationship between the two vision sensors is described in detail below with reference to fig. 6.
Two visual sensors scan a plurality of positions of the calibration ball in the measurement space at the same time, three-dimensional reconstruction is carried out to fit the coordinates of the center of the calibration ball at different positions, and the position relation between the devices is solved by using a rigid body transformation method.
Specifically, the step of calibrating the system coordinate system of the blade digital template detection system comprises the following steps:
placing a calibration ball at the edge of the turntable;
the spherical center coordinates of the calibration ball are fitted through scanning reconstruction of the first vision sensor;
keeping the calibration ball and the turntable relatively static, rotating the turntable, and repeating the scanning, reconstruction and fitting steps to obtain the coordinates of the center of the calibration ball at a plurality of positions;
and fitting a rotary shaft and a rotary center of the rotary table to obtain a system coordinate system and obtain a conversion relation between the measurement coordinate system and the system coordinate system.
The system coordinate system calibration is described in detail below with reference to fig. 7.
The calibration ball is placed at the edge of the rotary table, a visual sensor is used for scanning and reconstructing to fit a spherical center coordinate, the rotary table is rotated, the spherical center coordinates of a plurality of positions are obtained by repeating the above actions, a rotary shaft and a rotary center of the rotary table are fitted, a z-axis and an original point of a coordinate system of the rotary table, namely a system coordinate system, can be solved, the direction of the cross of the optical axis direction and the z-axis of the camera is an x-axis, and the direction of the cross of the z-axis and the x-axis is a y. And calibrating to obtain the conversion relation between the measurement coordinate system and the system coordinate system.
Preferably, the camera coordinate system of the first vision sensor comprises Pc1(Xc1，Yc1，Zc1) The measurement coordinate system of the first vision sensor comprises Pl1(Xl1，Yl1，Zl1) The camera coordinate system of the second vision sensor comprises Pc2(Xc2，Yc2，Zc2) The measurement coordinate system of the second vision sensor comprises Pl2(Xl2，Yl2，Zl2)。
Preferably, the system coordinate system of the blade digital template detection system comprises Ps(Xs，Ys，Zs)。
The following describes a specific implementation process of the calibration method of the blade digital template detection system provided by the present invention.
As shown in FIG. 3, the calibration sequence of the calibration method of the blade digitized template detection system comprises iterative camera calibration, laser knife plane calibration, measurement movement direction calibration, sensor relative position relationship calibration and system coordinate system calibration in sequence, wherein the calibration plate adopts a ceramic calibration plate with ring pattern characteristics, the ring rows and columns are distributed at 11 × 14, the interval is 15mm, the calibration balls are matte ceramic calibration balls with the theoretical diameter of 50mm and the actual three-coordinate measurement of 49.978 mm.
The specific content of the iterative camera calibration is to shoot calibration plate pictures under different poses, obtain camera calibration data by using an OpenCV function, obtain camera internal and external parameters according to a Zhang friend camera calibration method, convert an original image to a view of a calibration plate parallel to an image plane, manually select an ROI (region of interest) area to detect a central point of a circular ring, convert the obtained central point of the circular ring to an original image point, and calibrate the camera again by using corresponding data. And repeating the process until the calibration precision is not improved any more, and obtaining the internal and external parameters of the camera.
The specific process of laser knife plane calibration is shown in fig. 4, a plurality of groups of calibration plate images without laser and with laser are shot in a measurement space, each group of pictures is shot at first to obtain the calibration plate image without laser, the positions of the calibration plate and a camera are kept still, and after the calibration plate and the camera are turned down and exposed, the calibration plate image with the laser light bars in the same pose is shot. And acquiring the pose of the calibration plate under a camera coordinate system by using a PnP method, and extracting the light bar center of the picture with the laser stripes. And solving the physical coordinate value of the center of the optical strip according to the plane constraint provided By the calibration plate, and fitting the optical knife plane method Ax + By + Cz + D where the physical coordinate of the center of the optical strip is located By a least square optimization method to be 0. Establishing a representation of the measurement coordinate system in the camera coordinate system,[R，T]LaserInCam＝[XaxisYaxisZaxis]，[OxOyOz]T]wherein [ O ]xOyOz]TIs the expression of the vertical foot from the optical center of the video camera to the plane of the laser knife in the coordinate system of the camera, and the vertical foot passes through a straight line (At Bt Ct)]TWhere t is a free scalar and the equation introduced into the laser plane is
The direction of the Y axis of the measuring coordinate system which is the laser plane points to the origin of the coordinate system of the camera and is expressed as YaxisIn the first place, ((a, B, C)), the X-axis is the Y-axis and [ 001%]Is expressed as Xaxis＝cross(Yaxis，[001]) The Z axis is the cross product of the X axis and the Y axis and is expressed as Zaxis＝cross(Xaxis，Yaxis). Finally, the transformation between the camera coordinate system and the measurement coordinate system can be obtained by inversionlRTc＝[lRc，lTc]＝invers([R，T]LaserInCam)。
The measurement movement direction calibration process is shown in fig. 5, and is for calibrating the deviation between the Y-axis of the measurement coordinate system and the actual movement direction, which is still substantially in establishing the measurement coordinate system of the vision sensor. Keeping the calibration plate still in a view field, taking a picture every time the linear module of the blade digital sample plate measuring device carries the visual sensor and moves a small distance, obtaining the position and posture of the calibration plate when the visual sensor moves to different positions by using a PnP method, and obtaining a direction vector of the motion direction under a camera coordinate systemcYmExpressed in the measurement coordinate system aslYm＝lRc cYmWherein is the rotation of the camera coordinate system under the laser measurement coordinate systemlRc. When the linear module moves L, the transformation relation of the measurement coordinate system relative to the actual scanning coordinate system is
And converting the theoretical measurement coordinate system into a real scanning coordinate system after the calibration in the motion directionLower is Psc＝lYm *M+P1。
The calibration process of the relative position relationship between the two visual sensors is shown in fig. 6, a calibration ball is placed at any position in the visual field of the blade digital sample plate detection device, the two visual sensors are used for scanning and reconstructing point cloud of the calibration ball, after a plurality of positions are reconstructed respectively, the sphere center is fitted by using a least square method, and the rigid body transformation relationship is established by three-dimensional coordinates under the actual scanning coordinate systems of the two visual sensors.
The calibration process of the system coordinate system is as shown in fig. 7, a calibration ball is placed at a position of a turntable close to the edge, a first vision sensor is used for scanning and reconstructing a point cloud of the calibration ball, the position of the calibration ball relative to the turntable is kept still, the above operations are repeated after the turntable is rotated for one angle, the sphere center coordinates of a plurality of angles are used for fitting a circular plane of the turntable at the minimum, the normal direction of the plane of the turntable is used as the Z axis of the system coordinate system, the optical axis direction of a camera and the power direction of the Z axis are used as the X axis, and the Y axis is used as the power of the Z. Simultaneously obtaining the central coordinate S ═ X of the turntablesYsZs]And a transformation matrix of the system coordinate system under the camera coordinate systemcRTs. When the guide rail moves HcTransformation of a time camera coordinate system to a scanning coordinate system
Can obtain the transformation matrix of the scanning coordinate system under the system coordinate systemsRTsc＝(scRTc *cRTc)-1。
The calibration software is used for fitting the sphere center interactive interface to display that all calibration functions are integrated, and the shot picture and the point cloud reconstructed by scanning can be automatically stored in the corresponding calibration folder. After the point cloud is displayed in a three-dimensional mode, interaction such as point cloud storage, sphere center fitting, point cloud reselection, point selection, coordinate display and the like can be carried out on the point cloud in real time, and the fitted information is displayed in an information bar.
The blade digital template detection device has the measurement range of (1000 × ×) mm, the measurement depth of 200mm to 400mm, the CCD camera has higher shooting frame rate and higher resolution, the selected specifications are 149fps and 1280 ×, the baseline distance is 240mm, the imaging angle is 38.7 degrees, the weight is 3.5kg, the lens has the focal length of 8.0mm, the resolution is 120.001p/mm, the distortion rate is 0.60 percent, the power of a line laser is 100mw, the divergence angle is 60 degrees, after the system calibration is completed, the system is used for visual sensor repeatability error evaluation and system measurement error evaluation, the sensor repeatability error evaluation is that the laser of a visual sensor is fixed and hit at a certain position of a standard ball, the center of a laser light bar is shot and extracted 200 times at the position, the maximum error, the mean value and the standard difference of the vertical runout of the Y-axis of 200 times of each laser stripe point are calculated, the maximum error, the mean value and the mean value of the standard deviation of the optical stripe point are calculated, the optical stripe, the maximum error, the average value of the optical stripe extraction of the standard ball, the comparison result of the two optical stripe extraction of the standard ball, the comparison of the pixel of the standard ball, the comparison of the standard ball, the ceramic ball, the standard ball, the ceramic ball, the comparison of the pixel of the ceramic stripe extraction turntable is found, the standard ball is 500mm, the standard ball is found, the pixel of the ceramic stripe extraction, the.
Therefore, the calibration method of the blade digital template detection system provided by the invention is simple to operate, an operator only needs to prepare a general calibration plate and a calibration ball without manufacturing a specific calibration block, the calibration cost is reduced, the calibration plate is used for shooting pictures of camera calibration, laser plane calibration and measurement movement direction calibration, the calibration ball is used for scanning point cloud data files of position relation calibration and system coordinate system calibration between reconstruction equipment, and the operation is prompted according to calibration software, so that the output result of each calibration item can be obtained.
In addition, the calibration method of the blade digital sample plate detection system provided by the invention has high calibration efficiency, and the motion of the linear module is directly utilized for measuring the motion direction calibration without an additional high-precision motion mechanism. The calibration of the position relationship among the devices, the point cloud display in the system coordinate system calibration, the fitting of the sphere center and the interactive operation are integrated in the calibration software, and the point cloud sphere center fitting does not need to be carried out by third-party software. All calibrated results are automatically added into the measurement software of the blade digital sample plate detection device, and measurement can be carried out after calibration is finished.
As a second aspect of the present invention, there is provided a calibration apparatus for a blade digital template detection system, wherein, as shown in fig. 8, the calibration apparatus 10 for a blade digital template detection system comprises:
the camera calibration module 110, where the camera calibration module 110 is configured to perform camera calibration on the first visual sensor and the second visual sensor respectively to obtain camera parameters in a camera coordinate system;
the laser optical knife plane calibration module 120 is configured to perform laser optical knife plane calibration on the first vision sensor and the second vision sensor respectively to obtain measurement parameters in a measurement coordinate system;
a movement direction calibration module 130, where the movement direction calibration module 130 is configured to calibrate movement directions of the first visual sensor and the second visual sensor respectively according to the camera parameters and the measurement parameters, and obtain offsets between a Y axis of a measurement coordinate system of the first visual sensor and an actual movement direction of the second visual sensor respectively;
a first conversion module 140, wherein the first conversion module 140 is configured to convert the camera parameters of the first vision sensor and the second vision sensor from the camera coordinate system to the measurement coordinate system into measurement parameters in the measurement coordinate system, respectively;
a position relationship calibration module 150, where the position relationship calibration module 150 is configured to calibrate a position relationship between the first visual sensor and the second visual sensor;
a second conversion module 160, wherein the second conversion module 160 is configured to convert the measurement parameters in the measurement coordinate system of the second vision sensor into the measurement coordinate system of the first vision sensor;
a system coordinate system calibration module 170, wherein the system coordinate system calibration module 170 is used for performing system coordinate system calibration on the blade digital template detection system;
a third conversion module 180, where the third conversion module 180 is configured to convert the measurement coordinate system of the first vision sensor to the system coordinate system of the blade digital template detection system, so as to obtain the complete parameters of the blade digital template detection system in the system coordinate system.
The calibration device of the blade digital sample plate detection system provided by the invention is used for carrying out system calibration on the blade digital sample plate detection device which can rapidly scan the blade profile, obtain the complete point cloud of the blade, automatically analyze the measurement parameters and output the detection report. The device can be quickly calibrated by the universal calibration target, the camera calibration, the laser knife plane calibration, the measurement motion direction calibration, the equipment position relationship calibration and the system coordinate system calibration are completed, so that the interconversion relationship among the coordinate systems can be accurately obtained, the calibration cost is reduced, the complete calibration is realized, the calibration efficiency of the whole system can be improved, the system calibration process is simplified, and the applicability of the blade digital sample plate measuring device is realized.
The working principle of the calibration device of the blade digital template detection system provided by the invention can refer to the foregoing description, and the details are not repeated here.
It will be understood that the above embodiments are merely exemplary embodiments taken to illustrate the principles of the present invention, which is not limited thereto. It will be apparent to those skilled in the art that various modifications and improvements can be made without departing from the spirit and substance of the invention, and these modifications and improvements are also considered to be within the scope of the invention.
Claims (5)
1. A calibration method of a blade digital template detection system is characterized in that the blade digital template detection system comprises a first visual sensor and a second visual sensor, the first visual sensor and the second visual sensor are symmetrically arranged oppositely, and the calibration method of the blade digital template detection system comprises the following steps:
calibrating cameras of the first visual sensor and the second visual sensor respectively to obtain camera parameters under a camera coordinate system;
respectively calibrating the laser knife plane of the first vision sensor and the second vision sensor to obtain measurement parameters under a measurement coordinate system;
respectively calibrating the motion directions of the first visual sensor and the second visual sensor according to the camera parameters and the measurement parameters to respectively obtain the offset of the Y axis of the measurement coordinate system of the first visual sensor and the second visual sensor and the actual motion direction;
converting the camera parameters of the first vision sensor and the second vision sensor from the camera coordinate system to the measurement coordinate system respectively into measurement parameters in the measurement coordinate system;
calibrating the position relation of the first visual sensor and the second visual sensor;
converting the measurement parameters of the second vision sensor under the measurement coordinate system to the measurement coordinate system of the first vision sensor;
calibrating a system coordinate system of the blade digital sample plate detection system;
converting a measurement coordinate system under the first vision sensor into a system coordinate system of a blade digital template detection system to obtain complete parameters under the system coordinate system of the blade digital template detection system;
the laser knife plane calibration on the first visual sensor and the second visual sensor respectively to obtain the measurement parameters under the measurement coordinate system comprises:
shooting a plurality of groups of calibration plate images without laser stripes and with laser stripes by a camera calibrated by the camera;
acquiring the pose of a calibration plate under the camera coordinate system;
extracting the light strip center of the image with the laser strip;
calculating the physical coordinate value of the light bar center;
obtaining a laser light knife plane where the physical coordinate value of the center of the light bar is located by fitting to obtain a measurement coordinate system;
outputting the measurement coordinate system and the transformation relation between the measurement coordinate system and the camera coordinate system;
the acquiring of the pose of the calibration plate under the camera coordinate system comprises:
calculating the position poses of the n control points in a camera coordinate system according to the spatial position information of the n control points and the image point information of the n control points;
the laser knife plane where the physical coordinate values of the light bar centers are obtained through fitting comprises:
fitting a laser knife plane where the physical coordinate value of the light bar center is located by a least square optimization method;
wherein the calibrating the position relationship between the first visual sensor and the second visual sensor comprises:
the first visual sensor and the second visual sensor scan a plurality of positions of a calibration ball in a measurement space simultaneously;
respectively three-dimensionally reconstructing and fitting the coordinates of the sphere centers of the calibration spheres at different positions;
calculating the position relation between the first visual sensor and the second visual sensor by using rigid body change;
the step of calibrating the system coordinate system of the blade digital template detection system comprises the following steps:
placing a calibration ball at the edge of the turntable;
the spherical center coordinates of the calibration ball are fitted through scanning reconstruction of the first vision sensor;
keeping the calibration ball and the turntable relatively static, rotating the turntable, and repeating the scanning, reconstruction and fitting steps to obtain the coordinates of the center of the calibration ball at a plurality of positions;
and fitting a rotary shaft and a rotary center of the rotary table to obtain a system coordinate system and obtain a conversion relation between the measurement coordinate system and the system coordinate system.
2. The method for calibrating a blade digital template detection system according to claim 1, wherein the calibrating the motion directions of the first vision sensor and the second vision sensor according to the camera parameters and the measurement parameters respectively, and the obtaining the offset of the Y-axis of the measurement coordinate system of the first vision sensor and the second vision sensor from the actual motion direction comprises:
moving the first vision sensor and the second vision sensor on a plurality of positions on a moving module respectively, and shooting a calibration plate at each position of movement;
acquiring the pose of a calibration plate;
calculating a relative pose transform for each position of the first vision sensor and a relative pose transform for each position of the second vision sensor, respectively;
solving a direction vector of the motion direction under a camera coordinate system;
and outputting the direction vector.
3. A method for calibrating a blade digital template detection system according to claim 1 or 2, wherein the camera coordinate system of said first vision sensor comprises Pc1(Xc1,Yc1,Zc1) The measurement coordinate system of the first vision sensor comprises Pl1(Xl1,Yl1,Zl1) The camera coordinate system of the second vision sensor comprises Pc2(Xc2,Yc2,Zc2) The measurement coordinate system of the second vision sensor comprises Pl2(Xl2,Yl2,Zl2)。
4. A blade digital template detection system according to claim 3The calibration method is characterized in that the system coordinate system of the blade digital template detection system comprises Ps(Xs,Ys,Zs)。
5. A calibration device for a blade digital template detection system is characterized by comprising:
the camera calibration module is used for respectively calibrating the first visual sensor and the second visual sensor to obtain camera parameters under a camera coordinate system;
the laser optical knife plane calibration module is used for respectively carrying out laser optical knife plane calibration on the first vision sensor and the second vision sensor to obtain measurement parameters under a measurement coordinate system;
the motion direction calibration module is used for respectively calibrating the motion directions of the first visual sensor and the second visual sensor according to the camera parameters and the measurement parameters to respectively obtain the offset of the Y axis of the measurement coordinate system of the first visual sensor and the second visual sensor and the actual motion direction;
a first conversion module for converting the camera parameters of the first and second vision sensors from the camera coordinate system to the measurement coordinate system into measurement parameters in the measurement coordinate system, respectively;
the position relation calibration module is used for calibrating the position relation of the first visual sensor and the second visual sensor;
a second conversion module, configured to convert the measurement parameters in the measurement coordinate system of the second vision sensor into the measurement coordinate system of the first vision sensor;
the system coordinate system calibration module is used for calibrating a system coordinate system of the blade digital template detection system;
a third conversion module, configured to convert the measurement coordinate system of the first vision sensor to a system coordinate system of a blade digital template detection system, so as to obtain a complete parameter of the blade digital template detection system in the system coordinate system;
the laser knife plane calibration on the first visual sensor and the second visual sensor respectively to obtain the measurement parameters under the measurement coordinate system comprises:
shooting a plurality of groups of calibration plate images without laser stripes and with laser stripes by a camera calibrated by the camera;
acquiring the pose of a calibration plate under the camera coordinate system;
extracting the light strip center of the image with the laser strip;
calculating the physical coordinate value of the light bar center;
obtaining a laser light knife plane where the physical coordinate value of the center of the light bar is located by fitting to obtain a measurement coordinate system;
outputting the measurement coordinate system and the transformation relation between the measurement coordinate system and the camera coordinate system;
the acquiring of the pose of the calibration plate under the camera coordinate system comprises:
calculating the position poses of the n control points in a camera coordinate system according to the spatial position information of the n control points and the image point information of the n control points;
the laser knife plane where the physical coordinate values of the light bar centers are obtained through fitting comprises:
fitting a laser knife plane where the physical coordinate value of the light bar center is located by a least square optimization method;
wherein the calibrating the position relationship between the first visual sensor and the second visual sensor comprises:
the first visual sensor and the second visual sensor scan a plurality of positions of a calibration ball in a measurement space simultaneously;
respectively three-dimensionally reconstructing and fitting the coordinates of the sphere centers of the calibration spheres at different positions;
calculating the position relation between the first visual sensor and the second visual sensor by using rigid body change;
the step of calibrating the system coordinate system of the blade digital template detection system comprises the following steps:
placing a calibration ball at the edge of the turntable;
the spherical center coordinates of the calibration ball are fitted through scanning reconstruction of the first vision sensor;
keeping the calibration ball and the turntable relatively static, rotating the turntable, and repeating the scanning, reconstruction and fitting steps to obtain the coordinates of the center of the calibration ball at a plurality of positions;
and fitting a rotary shaft and a rotary center of the rotary table to obtain a system coordinate system and obtain a conversion relation between the measurement coordinate system and the system coordinate system.
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