CN109323665B - Precise three-dimensional measurement method for line-structured light-driven holographic interference - Google Patents
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- 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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Abstract
A precise three-dimensional measurement method for line-structured light-driven holographic interference solves the problem of generating a measurement path of a holographic interference sensor, and adopts the following steps: unified calibration of coordinates of line structured light scanning measurement and holographic interference measurement is carried out; scanning measurement and curve fitting; dividing and extending the curve; transforming a global coordinate system of the curve; all measurement paths of the holographic interferometry are generated. The beneficial effects are that: the mode of combining the low-cost linear structure optical sensor and the high-precision point optical ranging sensor is adopted, the clamping and positioning difficulty in the measuring process is reduced, the problem that each part needs to be subjected to coordinate system registration again in the traditional batch measuring process is converted into a stable solving problem which only needs one-time global calibration, and the automatic rapid precise three-dimensional measurement without registration of the blades in batches is realized.
Description
Technical Field
The invention belongs to the field of precision measurement, and particularly relates to a precision measurement method for line structured light driven holographic interference. The method is particularly suitable for non-contact rapid and precise measurement of complex curved surface parts such as aeroengines, gas turbine blades and the like.
Background
In the prior art, special-shaped parts with complex shapes, such as turbine blades or impellers, have high-performance surfaces, complex shapes and high measurement difficulty, and the aim of high-precision and high-efficiency coating-free measurement cannot be fulfilled by the prior art.
The blade is used as a critical part in an aeroengine and a gas turbine, the working environment of the blade is very severe, multiple loads such as aerodynamic force, centrifugal force and the like are borne, and any manufacturing defect influences the final working efficiency and the service life of the engine. Therefore, more and more blade manufacturing enterprises put forward the requirement of one hundred percent full inspection. The blade profile is designed according to the shape of a section line or a three-dimensional characteristic curved surface with parameters such as contour, bend angle, twist and the like.
The measuring methods mainly applied at present are special measuring tools, three-coordinate measuring machines and optical measuring methods. Optical measurements have recently gained increasing use, such as: structured light scanning methods, optical triangulation methods, holographic interferometry methods, and the like. The structured light scanning method can directly measure a common finish machining surface through algorithms and technologies such as exposure control optimization, image enhancement, multi-view measurement optimization and the like, and complete data (ten thousand points/second) of a free-form surface can be quickly obtained. However, due to the limitation of the measurement principle, the precise measurement of the high-curvature and small-radius features cannot be realized, and the measurement precision is low. And point light source measurement technologies (the minimum diameter of a light spot can reach 3.5 mu m) based on a light spot triangulation method, holographic interference and the like have the capability of measuring a high-reflection surface, do not need radius compensation, are matched with a precise motion control system, can realize precise measurement of characteristics of high curvature and small radius after a measurement path is planned, and have high measurement precision but low measurement efficiency. Optical measurement methods have become a development trend for the detection of complex curved surface parts. However, a single optical measurement method has obvious technical limitations, and is difficult to meet various requirements of high measurement speed, high precision, complete data and the like. Therefore, the method makes full use of the technical advantages of high scanning and measuring speed of the structured light and high holographic interference measuring precision, is an effective means for realizing rapid and accurate full-size measurement of complex special-shaped parts such as turbine blades, and further meets the measurement requirement of full-measurement and full-detection of the blades.
The holographic interference method can measure a metal surface with any brightness, but the measurement accuracy is ensured to be kept within an effective depth of field range (ensuring that a stable measurement distance is kept between a measuring head and a curved surface) in the measurement process. This requires path planning, which presupposes unification of the measurement coordinate system and the CAD model coordinate system. The problem of coordinate system registration is a great problem which puzzles the rapid and precise detection of the parts because the blade profiles are complex curved surfaces without characteristics. The invention combines the line structured light scanning measurement and the holographic interference method, and does not need to unify the measurement coordinate system and the CAD model coordinate system in the early period. And the full-size dense point cloud data of the blade surface is rapidly acquired. In summary, it would be very useful to provide a new system and method for rapid, precise, and low-cost measurement.
Disclosure of Invention
The invention aims to provide a precise three-dimensional measurement method for line-structured light-driven holographic interference. The method comprises the steps that a path of a holographic interference measurement system is planned to carry out measurement based on a measurement result of a line structured light scanning measurement system consisting of a binocular image sensor and a laser generator by means of four-axis linkage equipment, and the four-axis linkage equipment drives the holographic interference measurement system to carry out scanning measurement on a special-shaped workpiece with a complex shape according to the planned measurement path.
The technical scheme adopted by the invention for realizing the aim of the invention comprises the following steps:
step 1, unified parameter calibration of a global coordinate system of a linear structured light scanning measurement system and a holographic interference measurement system;
step 2, linear structure light scanning measurement and curve fitting; scanning and measuring a workpiece to be measured fixed on a rotary worktable of the four-axis linkage equipment by using a linear structured light scanning and measuring system, acquiring point cloud data on a group of measuring lines on the surface of the workpiece to be measured, and performing curve fitting according to the point cloud data on the group of measuring lines;
step 3, sequencing each curve in the group of curves fitted in the step 2, dividing each curve according to a midpoint, dividing the curve to obtain two curves, respectively extending the tangential directions of two end points according to a planned length to obtain two extended curves corresponding to the curve until the division and the extension of all the fitted curves are completed;
step 4, repeating the step 2 and the step 3 to complete the scanning measurement of all the measurement surfaces of the workpiece to be measured, performing curve fitting on the point cloud data on all the measurement lines obtained by the scanning measurement, and performing sequencing, segmentation and extension treatment on the fitted curve;
and 5, carrying out coordinate unified transformation on all the curves segmented and prolonged in the step 4 according to the global coordinate system unified parameters in the step 1 to generate all measurement paths of the holographic interference measurement system, and driving the holographic interference measurement system to carry out scanning measurement on the workpiece to be measured according to the measurement paths by the four-axis linkage equipment to obtain precise point cloud data of the surface of the workpiece to be measured.
The invention has the beneficial effects that: when the point light distance measuring sensor is used for measuring the turbine blade complex curved surface parts, a measuring path must be planned to obtain high precision. However, the measurement coordinate system and the CAD model coordinate system need to be unified for planning the measurement path, and there are problems that the time consumption is long, the measurement path is unstable, and the precision cannot be guaranteed. The method adopts a mode of combining the low-cost linear structured light sensor and the high-precision point light ranging sensor, and on the basis of unifying the global coordinate system, the structured light scanning data point cloud is used for generating the self-planning holographic interferometry, so that the clamping and positioning difficulty in the measuring process is reduced, the problem that each part needs to be registered again in the coordinate system in the traditional batch measuring process is converted into a stable solving problem which only needs one-time global calibration, and the automatic rapid three-dimensional measurement of the blades without registration in batch is realized.
The invention is described in further detail below with reference to the figures and examples.
Drawings
FIG. 1 is a flowchart of global coordinate system calibration in the measurement method of the present invention.
FIG. 2 is a schematic view of a structured light scanning measurement point cloud.
FIG. 3 is a schematic diagram of a fitting curve and a numbering curve.
Detailed Description
The working principle of the measuring method of the invention is as follows: firstly, calibrating a global coordinate system of a linear structured light sensor and a holographic interference sensor, so that the linear structured light vision sensor and the holographic interference sensor work in the same coordinate system; and then the linear structured light sensor carries out rapid scanning measurement on the special-shaped part such as a turbine blade to obtain a plurality of linear three-dimensional point cloud data of the part, curve fitting and data processing are carried out on the point cloud data to generate a holographic interference measurement path, the holographic interference sensor is driven by the four-axis control system to carry out fine measurement according to the generated path, and finally complete high-precision point cloud data of the part is obtained.
A precise three-dimensional measurement method for line-structured light-driven holographic interference is characterized in that a measurement path of a holographic interference measurement system is planned based on a measurement result of a line-structured light scanning measurement system consisting of a binocular image sensor and a laser generator by means of four-axis linkage equipment, the four-axis linkage equipment drives the holographic interference measurement system to perform scanning measurement on a measured workpiece according to the planned measurement path, and the method is realized by the following steps:
step 1, unified parameter calibration of a global coordinate system of the linear structured light scanning measuring system and the holographic interference measuring system.
The line-structured light sensor and the holographic interference sensor of the measuring system measure the calibration plate in the same pose, and each measured data describes the same object, so that the measured object can be considered to be transformed from one position to the other position in a global coordinate system through rigid body transformation. Therefore, the global coordinate unified transformation matrix and the translation vector are solved, so that the global coordinate system is calibrated uniformly, and the linear structured light sensor and the holographic interference sensor work in the same coordinate system.
Step 2, linear structure light scanning measurement and curve fitting; the method comprises the steps of using a linear structured light scanning measurement system to scan and measure a workpiece to be measured fixed on a rotary worktable of the four-axis linkage equipment, obtaining point cloud data on a group of measurement lines on the surface of the workpiece to be measured, and performing curve fitting according to the point cloud data on the group of measurement lines.
And 3, sequencing each curve in the group of curves fitted in the step 2, dividing each curve according to a midpoint, dividing the curve to obtain two curves, respectively extending the tangential directions of two end points according to a planned length to obtain two extended curves corresponding to the curve until the division and the extension of all the fitted curves are completed.
And 4, repeating the step 2 and the step 3 to complete the scanning measurement of all the measurement surfaces of the workpiece to be measured, performing curve fitting on the point cloud data on all the measurement lines obtained by the scanning measurement, and performing sequencing, segmentation and extension treatment on the fitted curve.
And 5, carrying out coordinate unified transformation on all the curves segmented and prolonged in the step 4 according to the global coordinate system unified parameters in the step 1 to generate all measurement paths of the holographic interference measurement system, and carrying out scanning measurement on the workpiece to be measured by the holographic interference measurement system formed by driving the point light distance measuring sensors through the four-axis linkage equipment according to the measurement paths to obtain precise point cloud data of the surface of the workpiece to be measured.
In the embodiment of the invention, the unified parameter calibration method of the global coordinate system of the line structure light scanning measurement system and the holographic interference measurement system in the step 1 comprises the following steps:
A. fixing a plane calibration plate with regularly arranged mark points on a workbench of four-axis linkage equipment, and respectively acquiring data of the plane calibration plate under a group of different installation postures by using a line structured light scanning and measuring system and a holographic interference measuring system, wherein the line structured light scanning and measuring system is used for shooting images of the calibration plate by using two cameras of the line structured light scanning and measuring system, and the holographic interference measuring system is used for acquiring point cloud data on the surface of the calibration plate;
B. a group of images collected based on A are used for carrying out parameter calibration on the linear structured light scanning measurement system, and internal parameters of the system are calibrated: focal length, image center, lens distortion and external parameters, and a rotation matrix and a translation vector between the two cameras;
C. marking the obtained internal and external parameters and the collected mark point information corresponding to the calibration plate by using the B calibration, and performing three-dimensional reconstruction on the mark points on the calibration plate;
D. performing plane fitting by adopting a random consistency algorithm based on the three-dimensional reconstruction result of the C to obtain a fitting plane of the fixed plate under each attitude;
E. and (3) calculating the distance from the point cloud data on the surface of the calibration plate acquired by the holographic interferometry system in the step A to the fitting plane D, solving the rotation matrix R and the translational vector T of the global coordinate system by minimizing the distance from the point to the plane, and finishing the unified calibration of the coordinate system.
In the embodiment of the present invention, the curve fitting method in step 2 is: the method for obtaining the point cloud data on a group of measuring lines on the surface of the workpiece to be measured comprises the following steps of: a cubic B spline interpolation fitting method is adopted, and the mathematical expression is as follows:
in the formula BiFor vertex control, k is the number of B-splines, here chosen to be 3, Ni,kFor standard B-spline basis functions, the parameter T constitutes a parameter set T ═ T0,t1,…tn+k-1,tn+kAnd the specific solving process is to construct a control point equation set of the B spline through a series of collected coordinate points, solve the control points by using the Clarit trigonometric decomposition, and then bring the control points into the formula to obtain the whole B spline curve.
Claims (3)
1. A line structure light-driven holographic interference precise three-dimensional measurement method is characterized in that a measurement path of a holographic interference measurement system is planned based on a measurement result of a line structure light scanning measurement system consisting of a binocular image sensor and a laser generator by means of four-axis linkage equipment, the four-axis linkage equipment drives the holographic interference measurement system to perform scanning measurement on a measured workpiece according to the planned measurement path, and the method is characterized in that: the method is realized by the following steps:
step 1, unified parameter calibration of a global coordinate system of a linear structured light scanning measurement system and a holographic interference measurement system;
step 2, linear structure light scanning measurement and curve fitting; scanning and measuring a workpiece to be measured fixed on a rotary worktable of the four-axis linkage equipment by using a linear structured light scanning and measuring system, acquiring point cloud data on a group of measuring lines on the surface of the workpiece to be measured, and performing curve fitting according to the point cloud data on the group of measuring lines;
step 3, sequencing each curve in the group of curves fitted in the step 2, dividing each curve according to a midpoint, dividing the curve to obtain two curves, respectively extending the tangential directions of two end points according to a planned length to obtain two extended curves corresponding to the curve until the division and the extension of all the fitted curves are completed;
step 4, repeating the step 2 and the step 3 to complete the scanning measurement of all the measurement surfaces of the workpiece to be measured, performing curve fitting on the point cloud data on all the measurement lines obtained by the scanning measurement, and performing sequencing, segmentation and extension treatment on the fitted curve;
and 5, carrying out coordinate unified transformation on all the curves segmented and prolonged in the step 4 according to the global coordinate system unified parameters in the step 1 to generate all measurement paths of the holographic interference measurement system, and driving the holographic interference measurement system by the four-axis linkage equipment to carry out scanning measurement on the workpiece to be measured according to the measurement paths to obtain precise point cloud data of the surface of the workpiece to be measured.
2. The precise three-dimensional measurement method for line-structured light-driven holographic interference according to claim 1, is characterized in that: step 1, the unified parameter calibration method of the global coordinate system of the line structure light scanning measurement system and the holographic interference measurement system is as follows:
A. fixing a plane calibration plate with regularly arranged mark points on a workbench of four-axis linkage equipment, and respectively acquiring data of the plane calibration plate under a group of different installation postures by using a line structured light scanning and measuring system and a holographic interference measuring system, wherein the line structured light scanning and measuring system is used for shooting images of the calibration plate by using two cameras of the line structured light scanning and measuring system, and the holographic interference measuring system is used for acquiring point cloud data on the surface of the calibration plate;
B. a group of images collected based on A are used for carrying out parameter calibration on the linear structured light scanning measurement system, and internal parameters of the system are calibrated: focal length, image center, lens distortion and external parameters, and a rotation matrix and a translation vector between the two cameras;
C. marking the obtained internal and external parameters and the collected mark point information corresponding to the calibration plate by using the B calibration, and performing three-dimensional reconstruction on the mark points on the calibration plate;
D. performing plane fitting by adopting a random consistency algorithm based on the three-dimensional reconstruction result of the C to obtain a fitting plane of the fixed plate under each attitude;
E. and (3) calculating the distance from the point cloud data on the surface of the calibration plate acquired by the holographic interferometry system in the step A to the fitting plane D, solving the rotation matrix R and the translational vector T of the global coordinate system by minimizing the distance from the point to the plane, and finishing the unified calibration of the coordinate system.
3. The precise three-dimensional measurement method for line-structured light-driven holographic interference according to claim 1, is characterized in that: the curve fitting method in the step 2 is as follows:
the method for obtaining the point cloud data on a group of measuring lines on the surface of the workpiece to be measured comprises the following steps of: a cubic B spline interpolation fitting method is adopted, and the mathematical expression is as follows:
in the formula BiFor vertex control, k is the number of B-splines, here chosen to be 3, Ni,kFor standard B-spline basis functions, the parameter T constitutes a parameter set T ═ T0,t1,…tn+k-1,tn+kAnd the specific solving process is to construct a control point equation set of the B spline through a series of collected coordinate points, solve the control points by using the Clarit trigonometric decomposition, and then bring the control points into the formula to obtain the whole B spline curve.
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| US11822287B1 (en) | 2022-08-01 | 2023-11-21 | Chris Hsinlai Liu | Binocular holographic machine vision system and method for identifying locations of target elements |
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