WO2017041418A1 - 多线阵列激光三维扫描系统及多线阵列激光三维扫描方法 - Google Patents

多线阵列激光三维扫描系统及多线阵列激光三维扫描方法 Download PDF

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WO2017041418A1
WO2017041418A1 PCT/CN2016/072450 CN2016072450W WO2017041418A1 WO 2017041418 A1 WO2017041418 A1 WO 2017041418A1 CN 2016072450 W CN2016072450 W CN 2016072450W WO 2017041418 A1 WO2017041418 A1 WO 2017041418A1
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laser
line
trigger signal
array
programmable gate
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PCT/CN2016/072450
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English (en)
French (fr)
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杜华
李仁举
叶成蔚
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天远三维（天津）科技有限公司
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Publication of WO2017041418A1 publication Critical patent/WO2017041418A1/zh

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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

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  • the invention relates to the technical field of three-dimensional scanning of the surface geometry of an object, in particular to a multi-line array laser three-dimensional scanning system and a multi-line array laser three-dimensional scanning method.
  • 3D scanning has been increasingly used in various fields as a fast 3D digital technology, including reverse engineering, industrial inspection, computer vision, CG production, etc., especially in the current rapid development of 3D printing and intelligent manufacturing.
  • 3D scanning has become an important part of the industry chain.
  • various applications have been proposed in the aspects of cost, practicability, accuracy and reliability of 3D scanning equipment. higher requirement.
  • Optical 3D scanning is the most common modern technology in the field of 3D digitization.
  • the combination of high measurement efficiency and high precision is a prominent feature of technology.
  • White light three-dimensional scanning is a traditional optical scanning technology. It is encoded and marked on the surface of the object by grating projection, and then taken by the camera for triangulation. It has been widely used in the field of three-dimensional measurement. It is characterized by high precision and high spatial resolution. The quality of the data is fine.
  • various complex environments have put forward new requirements for 3D scanning technology. For example, people hope that the device has higher scanning convenience and better optical anti-interference performance, and the scanning process can be more quickly and freely. Eliminate unnecessary links as much as possible and be able to perform measurements in most light environments.
  • the white light scanning device has limitations in volume and weight due to its own grating projector structure and measurement principle depending on timing coding, and requires a stable supporting structure such as a tripod to assist measurement, and the measurement convenience is limited; in addition, the white light source has limited brightness and measurement. It is greatly affected by optical properties such as ambient light and the color material of the object itself. It is difficult to measure effectively in a brighter environment or an object facing a darker color.
  • the single-line laser scanning technology is simpler to implement and lower in cost, but the scanning performance is greatly limited.
  • the scanning speed is slow, which makes the practicality limited.
  • the scanning speed of the multi-line laser scanning technology is greatly improved, but the laser is dependent on the special order. Generators, which are complex and costly, also hinder the widespread adoption of technology.
  • the scanning mis-splicing rate is high and the reliability is not guaranteed.
  • the traditional marker point splicing technique has the problem of high false splicing rate.
  • the performance is that the data of multiple scans is ambiguous when uniformly registered to the same coordinate system, resulting in a piece of scanned data being separated from the overall data and generating an error model.
  • This problem can be solved by manual deletion after each single-sided scanning in the white light three-dimensional scanning process, but it cannot be solved by the similar method in the laser three-dimensional scanning process in the continuous scanning mode, so it is usually necessary to rescan after the mis-splicing. , greatly affecting work efficiency.
  • the scanning accuracy is low.
  • the quality of laser scanning data is related to many factors. Among them, working distance control is an important factor. When the depth of field is certain, the change of working distance exceeds the depth of field will cause image blurring, resulting in large data noise and greatly reduced precision.
  • the working distance mainly depends on the operator's subjective judgment. In the process of continuous scanning, the working distance is difficult to accurately control, resulting in low scanning accuracy.
  • the present invention provides a multi-line array laser three-dimensional scanning system and a multi-line array laser three-dimensional scanning method that solve the above technical problems.
  • the present invention provides a multi-line array laser three-dimensional scanning system, including: multi-line An array laser three-dimensional scanning device and a host computer, the multi-line array laser three-dimensional scanning device comprising a programmable gate array FPGA, at least one stereoscopic image sensor, a line laser array and an error feedback controller, the programmable gate array FPGA and the The stereoscopic image sensor, the line laser array and the error feedback controller are respectively connected, and the upper computer is respectively connected to the programmable gate array FPGA and the stereoscopic image sensor;
  • the programmable gate array FPGA is configured to send a first trigger signal to the line laser array, so that the line laser array strobes the surface of the object to be measured according to the first trigger signal;
  • the programmable gate array FPGA is further configured to send a second trigger signal to the stereoscopic image sensor, so that the stereoscopic image sensor performs exposure shooting on the measured object according to the second trigger signal, and shoots Image pair is sent to the host computer;
  • the upper computer is further configured to perform error evaluation on the measurement data in real time and feed the evaluation result to the programmable gate array FPGA;
  • the programmable gate array FPGA is further configured to: after receiving the evaluation result fed back by the upper computer, send a control signal to the error feedback controller according to the evaluation result, and adjust the laser according to the evaluation result The distance between the three-dimensional scanning device and the measured object;
  • the upper computer is further configured to encode and decode a laser line in an image pair captured by the stereoscopic image sensor;
  • the upper computer is further configured to perform three-dimensional reconstruction on a feature point in an image pair of the measured object and a laser line reflected on a surface of the measured object;
  • the upper computer is further configured to register the three-dimensional laser line data on different frames to the same coordinate system to generate a shape point cloud based on the feature points.
  • the programmable gate array FPGA is further configured to receive a preset pulse trigger signal sent by the upper computer and a preset exposure time, and send the first to the line laser array according to the preset pulse trigger signal.
  • a trigger signal is sent to the stereoscopic image sensor according to the preset exposure time.
  • the error feedback controller is configured to receive a control signal sent by the programmable gate array FPGA, and output indicator light corresponding to the control signal.
  • the error feedback controller is a color changing LED lamp, including three primary colors of red, green, and blue. Combined light.
  • the stereoscopic image sensor is a multi-view visual image sensor composed of two or more optical cameras.
  • the stereoscopic sensor is provided with a lighting device.
  • the illumination time of the illumination device is synchronized with the exposure time of the stereo vision sensor.
  • the line laser array comprises a matrix arrangement of a plurality of line lasers.
  • the upper computer is configured to track the feature points, and register laser lines on different frames into the same coordinate system by tracking feature points of the same name between adjacent time frames.
  • the upper computer is further configured to evaluate a distance between the laser three-dimensional scanning device and the measured object in real time, and feed back an evaluation result to the programmable gate array FPGA when the distance exceeds a preset distance.
  • the host computer is further provided with a communication interface, wherein the communication interface is configured to communicate with a control device connected to the upper computer, so that the control device adjusts the multi-line array laser three-dimensional scanning device and The distance between the objects being measured.
  • the present invention also provides a multi-line array laser three-dimensional scanning method based on the above-described multi-line array laser three-dimensional scanning system, comprising:
  • the programmable gate array FPGA sends a first trigger signal to the line laser array, so that the line laser array strobes the surface of the object to be measured according to the first trigger signal;
  • the programmable gate array FPGA sends a second trigger signal to the stereoscopic image sensor, so that the stereoscopic image sensor performs exposure shooting on the measured object according to the second trigger signal, and sends the captured image pair To the upper computer;
  • the upper computer encodes and decodes a laser line reflected by a surface of the object to be measured in the image pair captured by the stereoscopic image sensor;
  • the upper computer performs three-dimensional reconstruction on the feature point of the object to be measured and the laser line reflected on the surface of the object to be measured in the image pair captured by the stereoscopic image sensor;
  • the upper computer registers the three-dimensional laser line data on different frames with the feature point as a reference. Forming a point cloud in the same coordinate system;
  • the upper computer performs error evaluation on the measurement data in real time and feeds the evaluation result to the programmable gate array FPGA;
  • the programmable gate array FPGA After receiving the evaluation result fed back by the upper computer, the programmable gate array FPGA sends a control signal to the error feedback controller according to the evaluation result, and adjusts the laser three-dimensional scanning device according to the evaluation result. The distance of the object being measured.
  • the method further includes:
  • the programmable gate array FPGA receives the preset exposure time and a preset pulse trigger signal, and sends a first trigger signal to the line laser array according to the preset pulse trigger signal, according to the preset exposure Time sends a second trigger signal to the stereoscopic image sensor.
  • the present invention provides a multi-line array laser three-dimensional scanning system and a multi-line array laser three-dimensional scanning method, which realizes precise synchronization and logic control of a multi-line array laser three-dimensional scanning system through a programmable gate array FPGA.
  • the line laser array is used as the projection pattern light source, and the trigger signal is sent to the stereoscopic image sensor and the line laser array through the programmable gate array FPGA, so that the upper computer receives the image pair captured by the stereoscopic image sensor, and the laser in the image pair
  • the line array pattern is coded and decoded and 3D reconstructed.
  • the surface feature points of the measured object are reconstructed in three dimensions and the 3D feature points are matched and aligned at different time.
  • the optical tracking technology is used to predict and correct the matching calculation for time domain laser 3D scanning.
  • the registration of the data is spliced, and the measurement error level is evaluated in real time and fed back to the error feedback controller to make an adjustment instruction, thereby completing the laser three-dimensional scanning with low cost, high efficiency, high reliability and high precision.
  • FIG. 1 is a schematic structural diagram of a multi-line array laser three-dimensional scanning system according to an embodiment of the present invention
  • FIG. 2 is a schematic structural diagram of a multi-line array laser three-dimensional scanning device according to an embodiment of the present invention
  • FIG. 3 is a schematic flow chart of a working method of a programmable gate array FPGA according to an embodiment of the present invention
  • FIG. 4 is a schematic flow chart of a method for encoding a laser line array by a host computer according to an embodiment of the present invention
  • FIG. 5 is a schematic flowchart of a three-dimensional scanning method based on a multi-line array laser three-dimensional scanning system according to an embodiment of the present invention
  • FIG. 6 is a schematic flow chart of a three-dimensional scanning method based on a multi-line array laser three-dimensional scanning system according to another embodiment of the present invention.
  • the multi-line array laser three-dimensional scanning system in the present application is illustrated, as shown in FIG. 1 , wherein the multi-line array laser three-dimensional scanning system includes a programmable gate array FPGA, at least one visual image sensor, a line laser array, and error feedback.
  • the controller and the host computer can be understood as a control device, such as a computer. It has the functions of laser line code decoding, 3D reconstruction, optical tracking positioning and error evaluation calculation.
  • the invention realizes precise synchronization and logic control of the multi-line array laser three-dimensional scanning system based on the programmable gate array FPGA, adopts the group line laser array as the projection pattern light source, and the multi-laser line coding and decoding unit marks the laser line, and the optical tracking technology
  • the dynamic feature point positioning registration is predicted and corrected, the measurement error level is evaluated in real time and fed back to the hardware system to make adjustment instructions, thereby completing low-cost, high-efficiency, high-reliability and high-precision laser three-dimensional scanning.
  • the multi-line array laser three-dimensional scanning device comprises a programmable gate array FPGA 101, at least one visual image Sensor 102, line laser array 103 and error feedback control
  • the programmable gate array FPGA 101 is connected to the stereoscopic image sensor 102, the line laser array 103 and the error feedback controller 104, respectively, and the upper computer 105 and the programmable gate array FPGA 101 and stereoscopic image respectively
  • the sensors 102 are connected;
  • the programmable gate array FPGA 101 is configured to send a first trigger signal to the line laser array 103, so that the line laser array 103 strobes the surface of the object to be measured according to the first trigger signal;
  • the programmable gate array FPGA 101 is further configured to send a second trigger signal to the stereoscopic image sensor 102, so that the stereoscopic image sensor 102 performs exposure shooting on the measured object according to the second trigger signal, and Send the captured image pair to the host computer;
  • the upper computer is further configured to perform error evaluation on the measurement data in real time and feed the evaluation result to the programmable gate array FPGA;
  • the programmable gate array FPGA is further configured to: after receiving the evaluation result fed back by the upper computer, send a control signal to the error feedback controller according to the evaluation result, and adjust the laser according to the evaluation result The distance between the three-dimensional scanning device and the measured object;
  • the upper computer 105 is further configured to encode and decode laser lines reflected by the surface of the object to be measured in the image pair captured by the stereoscopic image sensor 102, so that each laser line segment is uniquely coded and recognized.
  • the upper computer 105 is further configured to perform three-dimensional reconstruction on the image point of the object to be measured and the laser line reflected on the surface of the object to be measured in the image pair captured by the stereoscopic image sensor 102.
  • the upper computer 105 is further configured to track and locate optical feature points of the image centered by the stereoscopic image sensor 102, and establish matching between feature point sets on different time frames by using the tracked feature points as a reference. Corresponding the relationship and calculating the spatial positioning relationship, and then registering the 3D laser line data in different time frames to the same coordinate system according to the spatial positioning relationship, and splicing the laser lines to form a point cloud describing the shape of the object. At the same time, the 2D and 3D feature motion trajectories of the next frame are predicted.
  • the above system realizes precise synchronization and logic control of the multi-line array laser three-dimensional scanning system through the programmable gate array FPGA, and adopts the line laser array as the projection pattern light source, and sends the trigger signal to the stereoscopic image sensor and the line laser array through the programmable gate array FPGA.
  • the host computer receives the image pair captured by the stereoscopic image sensor and enters the laser line array pattern in the pair of images Line code decoding and 3D reconstruction, 3D reconstruction of the surface feature points of the measured object and 3D feature point matching alignment at different time points, using optical tracking technology to predict and correct the matching calculation, used for time domain laser 3D scanning data matching Quasi-splicing, simultaneous measurement error level evaluation and feedback to the error feedback controller to make adjustment instructions, thereby achieving low-cost, high-efficiency, high-reliability and high-precision laser three-dimensional scanning.
  • the programmable gate array FPGA 101 is further configured to receive a preset pulse trigger signal sent by the upper computer and a preset exposure time, and send the first to the line laser array according to the preset pulse trigger signal.
  • a trigger signal is sent to the stereoscopic image sensor according to the preset exposure time.
  • the programmable gate array FPGA 101 is connected to the stereoscopic image sensor 102, the line laser array 103, and the error feedback controller 104, respectively.
  • the programmable gate array FPGA is further configured to receive a preset pulse trigger signal sent by the upper computer and a preset exposure time, and send a first trigger signal to the line laser array according to the preset pulse trigger signal And transmitting a second trigger signal to the stereoscopic image sensor according to the preset exposure time.
  • the FPGA 101 sends a pulse trigger signal to the stereoscopic image sensor 102 and the line laser array 103, and precisely controls the stroboscopic illumination of the line laser array 103 and the synchronous shooting of the stereoscopic image sensor 102; the FPGA 101 communicates with the upper computer 105 to feed back the upper computer 105.
  • the measurement error evaluation level is converted to a logic signal control error feedback controller 104 to make an adjustment indication.
  • the scanning frequency is set by human-machine interaction of the upper computer 105; in S302, the upper computer 105 communicates with the stereoscopic image sensor 102 to detect a preset image capturing exposure time.
  • the upper computer 105 transmits the above exposure time to the FPGA 101; in S304, the FPGA 101 sets the pulse signal output width and the trigger output frequency according to the received exposure time and the scanning frequency; in S305, the FPGA 101 is directed to the line laser array 103 and the stereo
  • the visual image sensor 102 respectively emits a pulse trigger signal; in S306, the optical element (including the line laser array 103 and an auxiliary illumination light source that may be added on the stereoscopic image sensor 102) is energized on the rising edge of the pulse signal; in S307, stereoscopic vision The image sensor 102 starts exposure at the rising edge of the pulse signal; in S308, the stereoscopic image sensor is exposed to end, and an image pair acquisition is completed; in S309, the optical element is on the falling edge of the pulse The power is off; in S310, the hardware device waits for the next trigger of the FPGA 101 to loop to S305.
  • the stereoscopic image sensor 102 is a multi-view image sensor composed of two or more optical cameras.
  • the structure between the plurality of optical cameras is relatively fixed, and the relative positional relationship between the cameras and the internal parameters of the camera are Knowing that a plurality of cameras receive the trigger pulse signal sent by the FPGA 101, and the acquired images are exposed at the same time point, and the multiple images acquired each time form a set of stereo matching image pairs, which are transmitted to the upper computer 105 through the camera transmission cable, and are used for Three-dimensional reconstruction.
  • An illumination device is disposed in the vision sensor, and an illumination time of the illumination device is synchronized with an exposure time of the vision sensor.
  • the stereoscopic image sensor 102 includes an auxiliary illumination device for increasing the intensity of the reflected light of the surface of the measured object collected by the image acquisition sensor, for example, a ring concentric with the outer contour of the optical lens of the image acquisition sensor.
  • the LED light is connected to the camera through the camera's own signal input and output interface.
  • the flash signal function output by the interface can control the LED lamp to perform stroboscopic operation synchronized with the camera acquisition.
  • the present embodiment takes a stereo camera image sensor of a dual camera as an example. As shown in the structural diagram of FIG. 2, the dual camera is arranged above and below, so the upper camera is simply referred to as an upper camera, and the lower camera is simply referred to as a lower camera.
  • the line laser array 103 is composed of a plurality of line lasers in a matrix arrangement, the positional relationship between the line lasers is relatively fixed, and the positional relationship between the laser array 103 and the stereoscopic image sensor 102 is relatively fixed.
  • the line laser array 103 receives the pulse trigger signal sent by the FPGA 101, and is energized on the rising edge of the signal, and is turned off at the falling edge of the signal.
  • the projection pattern of the line laser array 103 irradiated onto the surface of the object to be measured is determined by the arrangement of the lasers.
  • a plurality of line lasers can be arranged in a variety of ways, and different projection patterns can be used to project different projection patterns, for example, a parallel arrangement in which lasers are uniformly aligned along the laser line direction, so that multiple laser lines are parallel.
  • the projection pattern is a set of parallel lines
  • a matrix arrangement when the laser array is vertically projected on a plane, the projection pattern is a set of grid lines
  • a random arrangement in which the projection pattern is a set of disordered linear clusters when the laser array is vertically projected on a plane.
  • the matrix array has the advantage that a maximum number of laser line arrays can be obtained in a limited device space to improve scanning efficiency and facilitate subsequent laser line coding implementation. Therefore, the matrix laser arrangement is taken as an example in this embodiment. As shown in component 103 in FIG.
  • the error feedback controller 104 includes a color changing LED lamp, a communication input interface, and a communication output interface.
  • the error feedback controller 104 receives the logic signal sent by the FPGA 101 through the communication input interface, and the LED light can emit at least 5 colors of light based on the combination of the three primary colors of red, green and blue, and the light of different colors represents different working distance indications.
  • the programmable gate array FPGA is configured to send the indication information of the three-dimensional scanning distance to the error feedback controller, so that the error feedback controller outputs indicator light corresponding to the indication information according to the indication information.
  • the host computer is further provided with a communication interface, wherein the communication interface is used for communicating with a control device connected to the upper computer, so that the control device adjusts between the multi-line array laser three-dimensional scanning device and the measured object. the distance.
  • the working distance control information is fed back to other automatic control devices connected to the system through the communication output interface, such as a robot, and the robot is instructed to adjust the working distance between the portable scanning sensing device and the measured object to realize intelligent scanning.
  • the upper computer has the function of laser line code decoding, and is used for encoding and decoding the group laser line pattern. Since the positional relationship between the line laser array 103 and the stereoscopic image sensor 102 is relatively fixed, the laser plane and the three-dimensional laser are emitted. The positional relationship between the visual image sensors 102 is also relatively fixed, so the laser plane equation is unique and fixed in the coordinate system bound to the scanning sensing device itself.
  • the processor encodes the laser plane where each laser line is located; in the three-dimensional scanning stage, each laser line is decoded using the laser plane attribute, so that each laser line is uniquely encoded for stereo matching. Three-dimensional reconstruction of the same encoded laser line in the image pair.
  • the specific implementation flow of the laser line array coding is shown in FIG. 4: in S401, the FPGA 101 control line laser array is turned on; in S402, the device is moved to the next preset working distance and the laser pattern is projected onto the reference plane. Since the laser plane intersects the reference plane in a three-dimensional space in a straight line, each laser line projected on the reference plane is a straight line; in S403, the FPGA 101 sends a trigger signal to control the stereoscopic image sensor 102 to expose the acquired image pair, according to According to the optical lens imaging principle, the collimated laser line pattern on the reference plane is still projected onto the imaging plane of the camera, that is, the laser line array pattern on the image is still a linear cluster array; In S404, the stereoscopic image sensor 102 transmits the acquired image pair to the upper computer 105; in S405, each image is subjected to image processing, all laser line center highlight pixels are extracted, and all laser lines are separated and extracted according to the linear nature, and according to The laser line arranges the two-dimensional
  • the laser line array decoding is performed in the three-dimensional scanning process, and each image is subjected to basic image processing, and the laser line is divided according to the continuity principle.
  • discrete pixel points on each laser line segment in the upper camera image respectively correspond to an image point on the imaging plane of the upper camera in three-dimensional space
  • the image point is connected to the optical and spatial laser of the optical center of the upper camera Plane intersection solves a three-dimensional point, and calculates the image point of the point on the lower camera image according to the camera imaging principle.
  • each laser segment performs the above calculation by traversing all laser planes, and can find the only corresponding laser plane and its code.
  • the upper computer has a three-dimensional reconstruction calculation function for three-dimensional reconstruction of the surface feature points of the object in the image pair acquired by the stereo vision sensor 102, and three-dimensional reconstruction of the laser line reflected by the surface of the object, that is, using the stereo matching image pair in the two-dimensional
  • the feature point set is transformed into a three-dimensional feature point set based on the triangulation calculation method, and the two-dimensional identical coded laser line in the stereo matching image pair is converted into a three-dimensional space laser line based on the triangulation calculation method.
  • the surface feature of the object is an artificially designed circular mark attached to the surface of the object, and the center of the ellipse extracted by the image processing is the two-dimensional image. Feature points.
  • the closest 2D feature point is searched on the polar line of the lower camera image, and the 2D feature point pair corresponding to the upper and lower cameras can be calculated according to the triangulation method.
  • the three-dimensional coordinates of the feature points For each laser spot in the upper camera image that has been decoded by the laser plane, the intersection of the polar line and the same encoded two-dimensional laser line segment is found on the lower camera image, and the two-dimensional laser point pair corresponding to the upper and lower cameras can be calculated according to the triangulation method.
  • the three-dimensional coordinates of the laser spot, the laser line is essentially a collection of these laser points.
  • the optical tracking and positioning function in the upper computer is used to track the feature points in the image sequence, and the matching correspondence between the feature point sets on different time frames is established by using the tracked feature points as a reference, and the spatial positioning relationship is calculated, and then according to The spatial positioning relationship registers the 3D laser line data in different time frames into the same coordinate system to form a point cloud describing the shape of the object.
  • the 2D and 3D feature motion trajectories of the next frame are tracked and predicted.
  • Optical feature tracking is first performed on a two-dimensional image. Since the camera performs image acquisition at a high frame rate and other time intervals, the motion velocity of the feature point on the two-dimensional image is approximately equal between adjacent frames, so according to t-2 And the pixel position of the feature point on the two-dimensional image at time t-1, the characteristic motion speed at time t-1 can be calculated, and according to the motion speed at time t-1 and the pixel position at the time, the feature point can be predicted at time t.
  • the pixel position, the two-dimensional feature point detected in the neighborhood of the predicted pixel position on the observed image at time t retains the feature point number at time t-1, and the feature points after the three-dimensional reconstruction are also kept numbered, that is, all tracking
  • the feature points that are obtained are numbered, meaning that the same numbered point can be found as the target point of the coordinate transformation in the three-dimensional feature point set before time t.
  • qi(xi,yi,zi) ⁇ constitutes a set of mapping relations, that is, coordinate transformation, there is a transformation relationship [R
  • T] that satisfies RXP+T XQ, where XP is the space coordinate vector in the point set P, XQ For the space coordinate vector in the point set Q, R is a 3 ⁇ 3 rotation matrix, and T is a 3 ⁇ 1 translation vector.
  • T] can be calculated by the least squares and quaternion method.
  • Point set P and Q visible optical tracking and positioning unit 1053 performs motion tracking on features, and uses tracking prediction to search for feature points of the same name between different time frames, which can speed up the registration speed of 3D feature point sets between different frames, and more importantly, exclude A misregistration scheme caused by a plurality of approximate triangle feature point distributions.
  • T coordinate transformation relationship
  • mi(xi, yi, zi) ⁇ reconstructed in three dimensions at time t can be transformed into the three-dimensional coordinates of all laser points by the operation of RXM+T.
  • the point cloud data in the same coordinate system is formed together with the point set before time t.
  • the error evaluation calculation function in the upper computer is used to evaluate the current measurement error level, and the error level result is fed back to the FPGA through the communication interface between the upper computer 105 and the FPGA 101.
  • the measurement error is based on the spatial coordinate of all the feature points of the three-dimensional reconstruction at time t to the average distance of the midpoint of the two camera optical center coordinate lines of the scanning sensing device (here defined as the working distance of the device) as a consideration for evaluating the measurement error level.
  • the working distance is within the range of the measured depth of field of the equipment, the error level is evaluated as 0, which means reasonable; when the working distance is larger or smaller than the depth of field range, the error level is evaluated as +1 or -1, indicating that the warning working distance should be adjusted.
  • the error evaluation function in the upper computer may also use the spatial coordinate of all laser points reconstructed by the object surface three-dimensionally and the average distance of the optical center of the device as the working distance, and evaluate the measurement error level.
  • FIG. 5 is a schematic flow chart of a multi-line array laser three-dimensional scanning method based on the multi-line array laser three-dimensional scanning system provided by the embodiment of the present invention, as shown in FIG. 5, including:
  • the programmable gate array FPGA sends a first trigger signal to the line laser array, so that the line laser array strobes the surface of the object to be measured according to the first trigger signal;
  • the programmable gate array FPGA sends a second trigger to the stereoscopic image sensor. a signal, so that the stereoscopic image sensor performs exposure shooting on the measured object according to the second trigger signal, and sends the captured image pair to the upper computer;
  • the upper computer encodes and decodes a laser line reflected by a surface of the object to be measured in the image pair captured by the stereoscopic image sensor;
  • the upper computer performs three-dimensional reconstruction on a feature point of the detected object in the image pair captured by the stereoscopic image sensor and a laser line reflected on a surface of the measured object;
  • the upper computer registers the three-dimensional laser line data on different frames to the same coordinate system to generate a point cloud according to the feature point;
  • the host computer performs error evaluation on the measurement data in real time and feeds the evaluation result to the programmable gate array FPGA;
  • the programmable gate array FPGA After receiving the evaluation result fed back by the upper computer, the programmable gate array FPGA sends a control signal to the error feedback controller according to the evaluation result, and adjusts the laser three-dimensional scan according to the evaluation result. The distance between the device and the object being measured.
  • the method further includes the steps not shown in the figure:
  • the programmable gate array FPGA receives the preset exposure time and a preset pulse trigger signal, and sends a first trigger signal to the line laser array according to the preset pulse trigger signal, according to the pre- The exposure time is set to send a second trigger signal to the stereoscopic image sensor.
  • FIG. 6 shows an overall implementation flow of a multi-line array laser three-dimensional scanning method according to the embodiment: in S601, the system performs initialization, and the upper computer 105 controls the FPGA 101 and the stereoscopic image sensor 102 to be turned on, and enters a working state; The FPGA 101 sends a trigger signal to control the optical component strobe and controls the stereoscopic image sensor 102 to start exposing the acquired image pair; in S603, the stereoscopic image sensor 102 transmits the acquired image pair to the upper computer 105; in S604, the upper computer passes the laser line The array coding and decoding function decodes and identifies the laser line, and identifies the laser plane number for each laser line segment on the image.
  • the upper computer performs three-dimensional reconstruction of the laser line and the feature point through the three-dimensional reconstruction calculation function; in S606, the upper computer passes the optical Tracking and locating function for feature point tracking and positioning, data registration and tracking prediction; in S607, the upper computer passes the error level evaluation calculation function Performing measurement error level evaluation calculation; in S608, the upper computer 105 sends the error level to the FPGA 101; in S609, the FPGA 101 outputs an indication according to the error level control error feedback controller 104; in S610, the working distance is adjusted according to the error feedback controller prompt; S611 Wait for the next FPGA trigger signal and jump to S602 to enter the loop.
  • the portable multi-line array laser three-dimensional scanning device mainly comprises a programmable gate array FPGA 101, a stereoscopic image sensor 102, a line laser array 103, and an error feedback controller.
  • the line laser array 103 emits a set of laser planes, which are projected onto a surface 501 of the object to be measured, and a set of laser line arrays 502, which are commonly used for optical three-dimensional scanning, are used for multiple times. Registration stitching between scanned data.
  • the scanning efficiency of the above system is greatly improved.
  • the data reconstruction efficiency is multiplied by using a laser line array pattern compared to a single laser line scan in the prior art. If the number of laser lines in the array is n, the amount of data reconstructed per unit time is n times that of a single line scan, that is, when the same amount of data is scanned, the laser line array scans only 1/n of the single line scan. For example, an array consisting of six line lasers has a scanning efficiency of about 6 times that of a single line scan and a scan time of 5/6.
  • the service life has increased dramatically. Limited by the processing speed of the image acquisition sensor, the effective exposure time of the image accounts for about 1/10 of the total scanning time. Therefore, in the continuous scanning mode of the prior art, the main optical LED components (such as laser LEDs) have up to 9 /10 invalid working time, and after pulse stroboscopic scanning, the proportion of invalid working time of the main optical LED components is reduced from 9/10 to 0. According to the LED nominal parameters, the service life is increased by more than 10 times. Significantly reduced, heat dissipation is almost negligible, while eliminating the cost of design and manufacturing of the heat sink structure.
  • the main optical LED components such as laser LEDs
  • the scanning mis-splicing rate is reduced and the reliability is improved.
  • the optical tracking and positioning technology improves the reliability of feature point matching, thereby improving the scanning data stitching registration.
  • the correct rate Taking the scanning of objects with 200 positioning reference points as an example, the two techniques are scanned 50 times for experimental statistics.
  • the probability of mis-splicing by single positioning technology is about 50%, and the number of mis-splicing by optical tracking and positioning technology is 0. .
  • the scanning accuracy is significantly improved.
  • the laser scanning accuracy is increased from 0.1mm to 0.03mm, which is about 3 times of the original.

Abstract

一种多线阵列激光三维扫描系统及多线阵列激光三维扫描方法，该系统通过可编程门阵列FPGA（101）实现多线阵列激光三维扫描系统的精确同步和逻辑控制，采用线激光器阵列（103）作为投影图案光源，通过可编程门阵列FPGA（101）向立体视觉图像传感器（102）和线激光器阵列（103）发送触发信号，上位机（105）接收到立体视觉图像传感器（102）拍摄的图像对，并对该图像对中的激光线阵图案进行编码解码及三维重建，对被测物体表面特征点进行三维重建和不同时刻间三维特征点匹配对齐，采用光学跟踪技术对匹配计算进行预测和纠错，用于时域激光三维扫描数据的配准拼接，同时实时进行测量误差等级评估并反馈至误差反馈控制器做出调整指示，从而完成低成本、高效率、高可靠性和高精度的激光三维扫描。

Description

多线阵列激光三维扫描系统及多线阵列激光三维扫描方法 技术领域
本发明涉及物体表面几何形状的三维扫描技术领域，尤其涉及一种多线阵列激光三维扫描系统及多线阵列激光三维扫描方法。
背景技术
近年来，三维扫描作为一种快速三维数字化技术被越来越多地应用在各个领域，包括逆向工程、工业检测、计算机视觉、CG制作等等，特别是在当前发展迅猛的3D打印和智能制造领域，三维扫描作为前端三维数字化和三维视觉传感技术，已经成为产业链上的重要一环；同时，各类应用在三维扫描设备的成本、实用性、精确性和可靠性等诸多方面提出了更高的要求。
光学三维扫描是三维数字化领域最常见的一种现代化技术手段，较高测量效率和较高的精度兼备是技术的突出特点。白光三维扫描是一种传统的光学扫描技术，通过光栅投影在物体表面进行编码标记，再由相机拍照进行三角测量，在三维测量领域已经被广泛应用，其特点是精度高、空间分辨率高，数据质量较为精细。随着应用领域的不断扩展，各种复杂使用环境对三维扫描技术提出了新的要求，例如人们希望设备具有更高的扫描便捷性以及更好的光学抗干扰性能，扫描流程能够更加快速自如，尽可能地省去不必要的环节，并能够在大多数的光线环境下完成测量。白光扫描设备由于自身的光栅投影器结构以及依赖时序编码的测量原理限制，体积和重量较大，并且需要三脚架等稳定支撑结构辅助测量，测量便捷性有所局限；另外，白光光源亮度有限，测量受环境光和物体本身颜色材质等光学属性影响较大，在较亮的环境中或面向较深颜色的物体，都难以进行有效测量。
为了弥补白光三维扫描技术的不足，一种以线激光作为光源的扫描技术应运而生，该技术仍然是基于多目视觉的三角测量原理，不同的是采用线激光作为图案投影器，图案简单且不随时间改变，激光器小巧结构简单，扫描设备随之变得轻便，且无需额外支撑稳定装置辅助测量，可以手持测量是其 典型特征；同时，激光线中心亮度极高，可以适应大多数光线环境或深色物体对象的扫描。然而现有的激光三维扫描技术在面向整个三维扫描领域普及之前，仍然存在几大重要问题亟待解决：
扫描效率与成本优势不可兼得。单线激光扫描技术实现较为简单，成本较低，但扫描性能受到很大限制，扫描速度慢，使得实用性有限；而多线激光扫描技术扫描速度有较大提升，但由于依赖特殊订制的激光发生器，工艺复杂且成本很高，同样为技术的普及应用带来阻碍。
使用寿命低。持续满功率的扫描工作使得光学器件特别是各类LED元件(激光器LED以及LED照明灯等)光衰加剧直接导致扫描性能(包括数据质量和扫描速度)下降；另外，持续工作的LED大量发热也带来设备散热问题，良好的散热性能与小巧轻便的整体结构要求相矛盾，而散热性能不好除了造成光学元件过早失效外，还可能影响整个扫描结构发生微小变形，导致扫描精度的损失。
扫描误拼接率较高，可靠性缺乏保障。传统的标记点拼接技术存在误拼接率高的问题，其表现是多次扫描的数据在统一配准到同一个坐标系时出现歧义，导致某片扫描数据脱离整体数据，生成错误模型。这个问题在白光三维扫描过程中可以在每次单面扫描之后通过手动删除等方法解决，但在连续扫描模式下的激光三维扫描过程中无法采用类似方法解决，因此出现误拼接后通常需要重新扫描，大大影响工作效率。
扫描精度低。激光扫描数据质量与多种因素有关，其中工作距离控制是一大重要因素，景深一定的情况下，工作距离变化超过景深大小会造成图像模糊导致数据噪声大，精度大幅降低。传统的激光扫描技术中工作距离主要依靠操作人员主观判断，在持续扫描的过程中工作距离难以准确控制，导致扫描精度较低。
发明内容
针对现有技术中的缺陷，本发明提供了解决上述技术问题的一种多线阵列激光三维扫描系统及多线阵列激光三维扫描方法。
第一方面，本发明提供了一种多线阵列激光三维扫描系统，包括：多线 阵列激光三维扫描设备和上位机，所述多线阵列激光三维扫描设备包括可编程门阵列FPGA、至少一个立体视觉图像传感器、线激光器阵列和误差反馈控制器，所述可编程门阵列FPGA与所述立体视觉图像传感器、线激光器阵列和误差反馈控制器分别相连，所述上位机分别与所述可编程门阵列FPGA和立体视觉图像传感器相连；
所述可编程门阵列FPGA，用于向所述线激光器阵列发送第一触发信号，以使所述线激光阵列根据所述第一触发信号频闪照射被测物体的表面；
所述可编程门阵列FPGA，还用于向所述立体视觉图像传感器发送第二触发信号，以使所述立体视觉图像传感器根据所述第二触发信号对被测物体进行曝光拍摄，并将拍摄的图像对发送至上位机；
所述上位机，还用于对测量数据实时进行误差评估并将评估结果反馈至可编程门阵列FPGA；
所述可编程门阵列FPGA，还用于在接收到所述上位机反馈的评估结果后，根据所述评估结果向所述误差反馈控制器发送控制信号，并根据所述评估结果调整所述激光三维扫描设备与被测物体的距离；
所述上位机，还用于对所述立体视觉图像传感器拍摄的图像对中的激光线进行编码和解码；
所述上位机，还用于对被测物体图像对中的特征点以及所述被测物体的表面反射的激光线进行三维重建；
所述上位机，还用于以所述特征点为基准，将不同帧上的三维激光线数据配准到同一坐标系中生成形面点云。
可选的，所述可编程门阵列FPGA，还用于接收所述上位机发送的预设脉冲触发信号和预设曝光时间，根据所述预设脉冲触发信号，向所述线激光器阵列发送第一触发信号，根据所述预设曝光时间向所述立体视觉图像传感器发送第二触发信号。
可选的，所述误差反馈控制器，用于接收所述可编程门阵列FPGA发送的控制信号，输出与所述控制信号对应的指示灯光。
可选的，所述误差反馈控制器为变色LED灯，包括红、绿、蓝三种基色 组合的光。
可选的，所述立体视觉图像传感器为多目视觉图像传感器，由两个或两个以上的光学相机组成。
可选的，所述立体视觉传感器中设置有照明装置。
可选的，所述照明装置的照射时间与所述立体视觉传感器的曝光时间同步。
可选的，所述线激光器阵列包括由多个线激光器按照矩阵式的排列方式组成。
可选的，所述上位机，用于对所述特征点进行跟踪，并通过跟踪相邻时间帧间的同名特征点，将不同帧上的激光线配准到同一坐标系中。
可选的，所述上位机，还用于实时评估所述激光三维扫描设备与被测物体的距离，并在所述距离超出预设距离时，向所述可编程门阵列FPGA反馈评估结果。
可选的，所述上位机上还设置有通讯接口，所述通讯接口用于向与所述上位机连接的控制设备进行通讯，以使所述控制设备调整所述多线阵列激光三维扫描设备与被测物体间的距离。
第二方面，本发明还提供了一种基于上述的多线阵列激光三维扫描系统的多线阵列激光三维扫描方法，包括：
所述可编程门阵列FPGA向所述线激光器阵列发送第一触发信号，以使所述线激光阵列根据所述第一触发信号频闪照射被测物体的表面；
所述可编程门阵列FPGA向所述立体视觉图像传感器发送第二触发信号，以使所述立体视觉图像传感器根据所述第二触发信号对被测物体进行曝光拍摄，并将拍摄的图像对发送至上位机；
所述上位机对所述立体视觉图像传感器拍摄的图像对中被测物体的表面反射的激光线进行编码解码；
所述上位机对所述立体视觉图像传感器拍摄的图像对中被测物体特征点以及所述被测物体的表面反射的激光线进行三维重建；
所述上位机以所述特征点为基准，将不同帧上的三维激光线数据配准到 同一坐标系中生成形面点云；
所述上位机对测量数据实时进行误差评估并将评估结果反馈至可编程门阵列FPGA；
所述可编程门阵列FPGA在接收到所述上位机反馈的评估结果后，根据所述评估结果向所述误差反馈控制器发送控制信号，并根据所述评估结果调整所述激光三维扫描设备与被测物体的距离。
可选的，在所述可编程门阵列FPGA向所述线激光阵列发送第一触发信号之前，所述方法还包括：
所述可编程门阵列FPGA接收所述上位机发送预设曝光时间以及预设脉冲触发信号，根据所述预设脉冲触发信号向所述线激光阵列发送第一触发信号，根据所述预设曝光时间向所述立体视觉图像传感器发送第二触发信号。
由上述技术方案可知，本发明提供一种多线阵列激光三维扫描系统及多线阵列激光三维扫描方法，该系统通过可编程门阵列FPGA实现多线阵列激光三维扫描系统的精确同步和逻辑控制，采用线激光器阵列作为投影图案光源，通过可编程门阵列FPGA向立体视觉图像传感器和线激光器阵列发送触发信号，使得上位机接收到立体视觉图像传感器拍摄的图像对，并对该图像对中的激光线阵图案进行编码解码及三维重建，对被测物体表面特征点进行三维重建和不同时刻间三维特征点匹配对齐，采用光学跟踪技术对匹配计算进行预测和纠错，用于时域激光三维扫描数据的配准拼接，同时实时进行测量误差等级评估并反馈至误差反馈控制器做出调整指示，从而完成低成本、高效率、高可靠性和高精度的激光三维扫描。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些图获得其他的附图。
图1是本发明一实施例提供的多线阵列激光三维扫描系统的结构示意图；
图2为本发明一实施例提供的多线阵列激光三维扫描设备的结构示意图；
图3是本发明一实施例提供的可编程门阵列FPGA工作方法的流程示意图；
图4为本发明一实施例提供的上位机对激光线阵列进行编码方法的流程示意图；
图5为本发明一实施例提供的基于多线阵列激光三维扫描系统进行三维扫描方法流程示意图；
图6为本发明另一实施例提供的基于多线阵列激光三维扫描系统进行三维扫描方法流程示意图。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
首先对本申请中的多线阵列激光三维扫描系统进行说明，如图1所示，其中所述多线阵列激光三维扫描系统包括可编程门阵列FPGA、至少一个视觉图像传感器、线激光器阵列、误差反馈控制器和上位机，该上位机可以理解为操控设备，例如：计算机。其具有激光线编码解码、三维重建、光学跟踪定位和误差评估计算的功能。
本发明基于可编程门阵列FPGA实现多线阵列激光三维扫描系统的精确同步和逻辑控制，采用群组线激光器阵列作为投影图案光源，多激光线编码解码单元对激光线进行标号识别，光学跟踪技术对动态特征点定位配准进行预测和纠错，实时进行测量误差等级评估并反馈至硬件系统做出调整指示，从而完成低成本、高效率、高可靠性和高精度的激光三维扫描。
在一种多线阵列激光三维扫描系统中包括：多线阵列激光三维扫描设备和上位机，如图2所示，所述多线阵列激光三维扫描设备包括可编程门阵列FPGA101、至少一个视觉图像传感器102、线激光器阵列103和误差反馈控制 器104，所述可编程门阵列FPGA101与所述立体视觉图像传感器102、线激光器阵列103和误差反馈控制器104分别相连，所述上位机105分别与所述可编程门阵列FPGA101和立体视觉图像传感器102相连；
所述可编程门阵列FPGA101，用于向所述线激光器阵列103发送第一触发信号，以使所述线激光器阵列103根据所述第一触发信号频闪照射被测物体的表面；
所述可编程门阵列FPGA101，还用于向所述立体视觉图像传感器102发送第二触发信号，以使所述立体视觉图像传感器102根据所述第二触发信号对被测物体进行曝光拍摄，并将拍摄的图像对发送至上位机；
所述上位机，还用于对测量数据实时进行误差评估并将评估结果反馈至可编程门阵列FPGA；
所述可编程门阵列FPGA，还用于在接收到所述上位机反馈的评估结果后，根据所述评估结果向所述误差反馈控制器发送控制信号，并根据所述评估结果调整所述激光三维扫描设备与被测物体的距离；
所述上位机105，还用于对所述立体视觉图像传感器102拍摄的图像对中被测物体的表面反射的激光线进行编码解码，使得各条激光线段被唯一编码识别。
所述上位机105，还用于对所述立体视觉图像传感器102拍摄的图像对中被测物体特征点以及所述被测物体的表面反射的激光线进行三维重建。
所述上位机105，还用于对所述立体视觉图像传感器102拍摄的图像对中光学特征点进行跟踪定位，并以跟踪到的特征点为基准参考建立不同时间帧上特征点集间的匹配对应关系并计算空间定位关系，再根据空间定位关系将不同时间帧上的三维激光线数据配准到同一坐标系中，并对激光线进行拼接，形成描述物体形面的点云。同时，预测下一帧二维和三维特征运动轨迹。
上述系统通过可编程门阵列FPGA实现多线阵列激光三维扫描系统的精确同步和逻辑控制，采用线激光器阵列作为投影图案光源，通过可编程门阵列FPGA向立体视觉图像传感器和线激光器阵列发送触发信号，使得上位机接收到立体视觉图像传感器拍摄的图像对，并对该图像对中的激光线阵图案进 行编码解码及三维重建，对被测物体表面特征点进行三维重建和不同时刻间三维特征点匹配对齐，采用光学跟踪技术对匹配计算进行预测和纠错，用于时域激光三维扫描数据的配准拼接，同时实时进行测量误差等级评估并反馈至误差反馈控制器做出调整指示，从而完成低成本、高效率、高可靠性和高精度的激光三维扫描。
具体的，上述所述可编程门阵列FPGA101，还用于接收所述上位机发送的预设脉冲触发信号和预设曝光时间，根据所述预设脉冲触发信号，向所述线激光器阵列发送第一触发信号，根据所述预设曝光时间向所述立体视觉图像传感器发送第二触发信号。
下面分别对上述系统中各部分的功能进行详细说明。
可编程门阵列FPGA101与立体视觉图像传感器102、线激光器阵列103以及误差反馈控制器104分别连接。所述可编程门阵列FPGA，还用于接收所述上位机发送的预设脉冲触发信号和预设曝光时间，并根据所述预设脉冲触发信号，向所述线激光阵列发送第一触发信号，根据所述预设曝光时间向所述立体视觉图像传感器发送第二触发信号。FPGA101向立体视觉图像传感器102和线激光器阵列103发送脉冲触发信号，精确控制线激光器阵列103的频闪照射以及立体视觉图像传感器102的同步拍摄；FPGA101与上位机105通讯，将上位机105反馈的测量误差评估等级转化为逻辑信号控制误差反馈控制器104作出调整指示。FPGA101精确同步控制的具体流程参照图3，在S301中，通过上位机105人机交互设定扫描频率；S302中，上位机105与立体视觉图像传感器102通讯，检测预先设定的图像采集曝光时间；S303中，上位机105将上述曝光时间发送至FPGA101；S304中，FPGA101根据接收到的曝光时间以及扫描频率设定脉冲信号输出宽度及触发输出频率；S305中，FPGA101向线激光器阵列103以及立体视觉图像传感器102分别发出脉冲触发信号；S306中，光学元件(包括线激光器阵列103以及立体视觉图像传感器102上可能附加的辅助照明光源等)在脉冲信号上升沿通电亮起；S307中，立体视觉图像传感器102在脉冲信号上升沿开始曝光；S308中，立体视觉图像传感器曝光结束，完成一次图像对采集；S309中，光学元件在脉冲下降沿 断电熄灭；S310中，硬件设备等待FPGA101下一次触发即循环至S305。
立体视觉图像传感器102是一种多目图像传感器，由两个或两个以上的多个光学相机组成，多个光学相机间的结构相对固定，且相机间的相对位置关系和相机内部参数是已知的，多个相机接收FPGA101发出的触发脉冲信号，在同一时间点曝光采集图像，每次采集的多幅图像组成一组立体匹配图像对，通过相机传输线缆传送至上位机105，用于三维重建。所述视觉传感器中设置有照明装置，所述照明装置的照射时间与所述视觉传感器的曝光时间同步。可选地，立体视觉图像传感器102包括一种辅助照明设备，用于增加图像采集传感器采集到的被测物体表面的反射光强度，例如，一种与图像采集传感器光学镜头外圆轮廓同心的环形LED灯，且通过相机自身的信号输入输出接口与相机连接，该接口输出的闪光灯信号功能可以控制LED灯进行与相机采集同步的频闪工作。为便于说明，本实施例以双相机的立体视觉图像传感器为例，如图2结构示意图所示，双相机以上下结构布置，故上方相机简称为上相机，下方相机简称为下相机。
线激光器阵列103由多个线激光器按照矩阵式的排列方式组成，线激光器间位置关系相对固定，激光器阵列103与立体视觉图像传感器102间位置关系相对固定。线激光器阵列103接收FPGA101发送的脉冲触发信号，在信号上升沿通电亮起，在信号下降沿断电熄灭。线激光器阵列103照射到被测物体表面的投影图案由激光器的排列方式决定。多个线激光器的排列方式可以是多样的，通过不同的结构排列，可以投射出不同的投影图案，例如，一种平行的排列方式，即激光器沿激光线方向一致排列，使得多条激光线平行出射，当激光阵列垂直投影在一个平面上时，投影图案为一组平行线；一种矩阵式的排列方式，当激光阵列垂直投影在一个平面上时，投影图案为一组网格线；一种随机的排列方式，当激光阵列垂直投影在一个平面上时，投影图案为一组无序的直线簇。其中，矩阵阵列的优点是在有限的设备空间内可以获得最大化数量的激光线阵列，以提升扫描效率，并且便于后续的激光线编码实现，因此本实施例以矩阵式的激光器排列方式为例，如图2中的部件103所示。
误差反馈控制器104包含一个变色LED灯、一个通讯输入接口和一个通讯输出接口。误差反馈控制器104通过通讯输入接口接收FPGA101发送的逻辑信号，LED灯基于红、绿、蓝三种基色组合可发出至少5种以上颜色的光，不同颜色的光代表不同的工作距离指示，所述可编程门阵列FPGA，用于向所述误差反馈控制器发送所述三维扫描距离的指示信息，以使所述误差反馈控制器根据所述指示信息输出与所述指示信息对应的指示灯光。例如，指示灯显示为绿色时，表示工作距离在合理范围内；指示灯显示为其它颜色时，表示工作距离不在合理范围内，或太近或太远，该指示可帮助人工操作时实时调整工作距离。所述上位机上还设置有通讯接口，所述通讯接口用于向与所述上位机连接的控制设备进行通讯，以使所述控制设备调整所述多线阵列激光三维扫描设备与被测物体间的距离。通过通讯输出接口将工作距离控制信息反馈至与系统连接的其它自动化控制设备，例如机器人，指示机器人调整所述便携式扫描传感设备与被测物体间的工作距离以实现智能化扫描。
上位机具有激光线编码解码的功能，用于对群组激光线图案进行编码和解码处理，由于线激光器阵列103与立体视觉图像传感器102间的位置关系相对固定，各激光器出射的激光平面与立体视觉图像传感器102间的位置关系同样相对固定，因此激光平面方程在与所述扫描传感设备自身绑定的坐标系中唯一且固定不变。在前期系统定标阶段，处理器对每条激光线所在激光平面进行编码；在三维扫描阶段，再利用激光平面属性对每条激光线进行解码，使得每条激光线编码唯一，用以立体匹配图像对中的相同编码激光线进行三维重建。
激光线阵列编码的具体实现流程如图4所示：S401中，FPGA101控制线激光器阵列开启；S402中，将设备移动至下一个预先设定的工作距离并将激光图案投影照射到参考平面上，由于激光平面与参考平面在三维空间中相交于一条直线，因此投影在参考平面上的各条激光线均为直线；S403中，FPGA101发送触发信号控制立体视觉图像传感器102曝光一次采集图像对，根据光学透镜成像原理，参考平面上的准直激光线图案投影到相机的成像平面上仍然为一条直线，即图像上的激光线阵列图案仍然为一个直线簇阵列； S404中，立体视觉图像传感器102将采集的图像对传送至上位机105；S405中，各图像分别进行图像处理，提取所有激光线中心高亮像素，根据直线性质分离提取出所有激光线，并根据激光线在图像上从上至下、从左至右的顺序对图像上的二维激光线进行排列；S406中，通过上位机中的三维重建计算功能按照匹配图像对中的对应序号激光线进行三维重建；S407中，将激光线上的离散三维点数据累积计入对应序号的激光平面上的观测点集{P|pi(xi,yi,zi)}；S408中，判断是否完成所有设定工作距离的采集；S409中，如果判断没有完成所有设定工作距离的采集，跳转至S402进入循环；如果判断已完成所有设定工作距离的采集，拟合所有激光平面方程。一般空间平面方程满足Ax+By+Cz+D＝0，空间平面上的三维观测点集{P|pi(xi,yi,zi)}满足该平面方程，利用最小二乘法可解算出A、B、C、D四个方程系数，每个激光平面有且只有一个平面方程，该平面方程的顺序编号即为激光平面的编码。
激光线阵列解码在三维扫描过程中进行，各图像分别进行基本图像处理，根据连续性原则进行激光线分割。在双相机图像采集系统中，上相机图像中的各激光线段上的离散像素点分别对应三维空间中上相机成像平面上的一个像点，该像点与上相机光学中心连接的射线与空间激光平面相交解得一个三维空间点，根据相机成像原理计算该点在下相机图像上的像点，若上相机图像中某激光线段上的大部分离散像素点通过上述方法在下相机图像上找到的对应像素点集恰好位于同一条激光线段上，则对上相机和下相机的这两条激光线段进行编号标识，编号与所采用的激光平面编号一致。通常情况下，各条激光线段通过遍历所有激光平面进行上述计算，都可以找出唯一对应的激光平面及其编码。
上位机具有三维重建计算功能，用于对立体视觉传感器102采集的图像对中的物体表面特征点进行三维重建，以及物体表面反射的激光线进行三维重建，即利用立体匹配图像对中的二维特征点集基于三角测量计算法转化为三维特征点集，将立体匹配图像对中的二维相同编码激光线基于三角测量计算法转化为三维空间激光线条。本实施例中，物体表面特征是一种粘贴在物体表面的人工设计的圆形标记，图像处理提取的椭圆中心即为图像上的二维 特征点。根据对极几何原理，对于上相机图像中的每个特征点，在下相机图像的极线上寻找距离最近的二维特征点，上下相机对应的二维特征点对根据三角测量法可计算出该特征点的三维空间坐标。对于上相机图像中的每个已被激光平面解码的激光点，在下相机图像上寻找极线与相同编码二维激光线段的交叉点，上下相机对应的二维激光点对根据三角测量法可计算出该激光点的三维空间坐标，激光线实质上是这些激光点的集合。
上位机中的光学跟踪定位功能，用于跟踪图像序列中的特征点，并以跟踪到的特征点为基准参考建立不同时间帧上特征点集间的匹配对应关系并计算空间定位关系，再根据空间定位关系将不同时间帧上的三维激光线数据配准到同一坐标系中，形成描述物体形面的点云，同时，跟踪预测下一帧二维和三维特征运动轨迹。
光学特征跟踪首先在二维图像上进行，由于相机在高帧率等时间间隔下进行图像采集，特征点在二维图像上的运动速度在相邻两帧之间近似相等，因此根据t-2和t-1时刻特征点在二维图像上的像素位置，可计算出t-1时刻的特征运动速度，根据t-1时刻的运动速度以及该时刻的像素位置，可以预测t时刻该特征点的像素位置，在t时刻的观测图像上预测像素位置的邻域内检测到的二维特征点保留t-1时刻的特征点编号，以此进行三维重建后的特征点同样保持编号，即所有跟踪到的特征点均被编号标识，意味着能够在t时刻以前的三维特征点集中找到相同编号的点作为坐标变换的目标点。若t时刻跟踪到的三维特征点数量不少于3个，且不在同一直线上，则这些点所构成的点集{P|pi(xi,yi,zi)}与相应的坐标变换目标点集{Q|qi(xi,yi,zi)}构成一组映射关系，即坐标变换，存在变换关系[R|T]满足RXP+T＝XQ,其中XP为点集P中的空间坐标向量，XQ为点集Q中的空间坐标向量，R为3×3的旋转矩阵，T为3×1的平移向量，利用最小二乘及四元数法可计算得到变换关系[R|T]。若t时刻跟踪到的点少于3个，那么需要以跟踪到的同名三维特征点为基准参考，在t时刻重建的三维特征点集{K|ki(xi,yi,zi)}中围绕跟踪到的已知编号的特征点进行三角剖分建立三角形集合，在t时刻前重建的特征点组成的三角形集合中搜索全等三角形，不同时刻的全等三角形的三个顶点构成坐标变 换关系，计算出[R|T]。若t时刻跟踪到的点数量为0，那么需要在t时刻重建的三维特征点集{K|ki(xi,yi,zi)}中将所有特征点进行三角剖分建立三角形集合，在t时刻前重建的特征点组成的三角形集合中搜索全等三角形，不同时刻的全等三角形的三个顶点构成坐标变换关系，计算出[R|T]。值得注意的是，在高帧率连续采集测量的工作情况下，时序上连续两帧之间的图像中目标位移量变化不大，因此在绝大部分时间内都可以通过特征跟踪找到匹配的特征点集P与Q，可见光学跟踪定位单元1053对特征进行运动跟踪，利用跟踪预测搜索不同时刻帧间的同名特征点，可以加快不同帧间3D特征点集的配准速度，更重要的是排除了多个近似三角形的特征点分布带来的错误配准方案。得到坐标变换关系[R|T]后，将t时刻三维重建的所有激光点集{M|mi(xi,yi,zi)}通过RXM+T的运算即可将所有激光点三维空间坐标变换至t时刻前统一的坐标系中，与t时刻前的点集一起构成同一个坐标系下的点云数据。
上位机中的误差评估计算功能，用于评估当前测量误差等级，并将误差等级结果通过上位机105与FPGA101的通讯接口反馈至FPGA。测量误差根据t时刻三维重建的所有特征点的空间坐标到扫描传感设备的两相机光学中心坐标连线中点的平均距离(此处定义为设备工作距离)作为评估测量误差等级的一个考量，当工作距离在设备测量景深范围内时，误差等级评估为0，表示合理；当工作距离与景深范围相比较大或较小时，误差等级评估为+1或-1，表示警示工作距离应当作出调整；当工作距离与景深范围相比过大或过小时，误差等级评估为+2或-2，表示工作距离必须作出调整，否则数据不再更新累积，防止影响整体数据质量。可选地，该上位机中的误差评估功能也可以采用物体表面三维重建的所有激光点的空间坐标与设备光学中心的平均距离作为工作距离，对测量误差等级进行评估。
图5示出了本发明实施例提供的一种基于上述的多线阵列激光三维扫描系统的多线阵列激光三维扫描方法的流程示意图，如图5所示，包括：
S501、所述可编程门阵列FPGA向所述线激光器阵列发送第一触发信号，以使所述线激光阵列根据所述第一触发信号频闪照射被测物体的表面；
S502、所述可编程门阵列FPGA向所述立体视觉图像传感器发送第二触发 信号，以使所述立体视觉图像传感器根据所述第二触发信号对被测物体进行曝光拍摄，并将拍摄的图像对发送至上位机；
S503、所述上位机对所述立体视觉图像传感器拍摄的图像对中被测物体的表面反射的激光线进行编码解码；
S504、所述上位机对所述立体视觉图像传感器拍摄的图像对中被测物体特征点以及所述被测物体的表面反射的激光线进行三维重建；
S505、所述上位机以所述特征点为基准，将不同帧上的三维激光线数据配准到同一坐标系中生成形面点云；
S506、所述上位机对测量数据实时进行误差评估并将评估结果反馈至可编程门阵列FPGA；
S507、所述可编程门阵列FPGA在接收到所述上位机反馈的评估结果后，根据所述评估结果向所述误差反馈控制器发送控制信号，并根据所述评估结果调整所述激光三维扫描设备与被测物体的距离。
步骤S501中在所述可编程门阵列FPGA向所述线激光阵列发送第一触发信号之前，所述方法还包括图中未示出的步骤：
S500、所述可编程门阵列FPGA接收所述上位机发送预设曝光时间以及预设脉冲触发信号，根据所述预设脉冲触发信号向所述线激光阵列发送第一触发信号，根据所述预设曝光时间向所述立体视觉图像传感器发送第二触发信号。
图6所示为本实施例的一种多线阵列激光三维扫描方法的整体实现流程：在S601中，系统进行初始化，上位机105控制FPGA101、立体视觉图像传感器102开启，进入工作状态；S602中，FPGA101发送触发信号控制光学元件频闪并控制立体视觉图像传感器102开始曝光采集图像对；S603中，立体视觉图像传感器102将采集的图像对传送至上位机105；S604中，上位机通过激光线阵列编码解码功能对激光线进行解码标识，为图像上的每条激光线段识别激光平面编号；S605中，上位机通过三维重建计算功能进行激光线和特征点三维重建；S606中，上位机通过光学跟踪定位功能进行特征点跟踪定位、数据配准及跟踪预测；S607中，上位机通过误差等级评估计算功能 进行测量误差等级评估计算；S608中，上位机105将误差等级发送至FPGA101；S609中，FPGA101根据误差等级控制误差反馈控制器104发出指示；S610中，根据误差反馈控制器提示调整工作距离；S611中，等待下一次FPGA触发信号，跳转至S602进入循环。
图2所示为本实施例的一种工作状态下的设备结构示意图，便携式多线阵列激光三维扫描设备主要由可编程门阵列FPGA101、立体视觉图像传感器102、线激光器阵列103以及误差反馈控制器104组成，线激光器阵列103出射一组激光平面，投影在被测物体表面501上一组激光线阵列502，圆形标记点503为光学三维扫描普遍使用的一种人工标记，用来进行多次扫描数据之间的配准拼接。
上述系统扫描效率大幅提升。采用激光线阵列图案与现有技术中的单激光线扫描相比，数据重建效率成倍增加。如果阵列中激光线数量为n，则在单位时间内重建的数据量是单线扫描的n倍，即在完成相同数据量的扫描情况下，激光线阵列扫描的时间只有单线扫描的1/n。例如，采用6个线激光器组成的阵列扫描效率约为单线扫描的6倍，扫描时间缩短5/6。
设备成本大幅下降。特殊订制的多线激光发生器工艺复杂，且技术被极少数公司垄断，成本很高，通常这类激光扫描设备的激光器成本在数万元人民币；而采用单线激光器阵列，同等激光线数量的激光器阵列成本只有几百元人民币，即激光器部分成本节省95/100以上，整个扫描设备的成本随之降低约2/3。
使用寿命大幅增加。受图像采集传感器的处理速度限制，图像有效曝光时间对扫描总时间的占比约为1/10,因此在现有技术的持续扫描模式下，主要光学LED元件(如激光LED等)有高达9/10的无效工作时间，而采用脉冲频闪式扫描后，主要光学LED元件的无效工作时间占比由9/10降为0，按照LED标称参数估计，使用寿命提升10倍以上，能耗大幅降低，散热几乎可忽略不计，同时省去了散热结构的设计和制造成本。
扫描误拼接率下降，可靠性提升。采用光学跟踪定位技术与现有的单一定位技术相比，提升了特征点匹配的可靠性，进而提升了扫描数据拼接配准 的正确率。以含200个定位参考标记点的物体扫描为例，两种技术分别扫描50次进行实验统计，单一定位技术出现误拼接的概率约为50％，而光学跟踪定位技术出现误拼接的次数为0。
扫描精度显著提升。根据国际权威的德国VDI-2634光学三维测量设备精度检测标准进行测试，采用误差评估及反馈控制技术后，激光扫描精度从0.1mm以上提升至0.03mm，为原来的3倍左右。
以上实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解；其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。

Claims (13)

  1. 一种多线阵列激光三维扫描系统，其特征在于，包括：多线阵列激光三维扫描设备和上位机，所述多线阵列激光三维扫描设备包括可编程门阵列FPGA、至少一个立体视觉图像传感器、线激光器阵列和误差反馈控制器，所述可编程门阵列FPGA与所述立体视觉图像传感器、线激光器阵列和误差反馈控制器分别相连，所述上位机分别与所述可编程门阵列FPGA和立体视觉图像传感器相连；
    所述可编程门阵列FPGA，用于向所述线激光器阵列发送第一触发信号，以使所述线激光阵列根据所述第一触发信号频闪照射被测物体的表面；
    所述可编程门阵列FPGA，还用于向所述立体视觉图像传感器发送第二触发信号，以使所述立体视觉图像传感器根据所述第二触发信号对被测物体进行曝光拍摄，并将拍摄的图像对发送至上位机；
    所述上位机，还用于对测量数据实时进行误差评估并将评估结果反馈至可编程门阵列FPGA；
    所述可编程门阵列FPGA，还用于在接收到所述上位机反馈的评估结果后，根据所述评估结果向所述误差反馈控制器发送控制信号，并根据所述评估结果调整所述激光三维扫描设备与被测物体的距离；
    所述上位机，还用于对所述立体视觉图像传感器拍摄的图像对中的激光线进行编码和解码；
    所述上位机，还用于对被测物体图像对中的特征点以及所述被测物体的表面反射的激光线进行三维重建；
    所述上位机，还用于以所述特征点为基准，将不同帧上的三维激光线数据配准到同一坐标系中生成形面点云。
  2. 根据权利要求1所述的系统，其特征在于，所述可编程门阵列FPGA，还用于接收所述上位机发送的预设脉冲触发信号和预设曝光时间，根据所述预设脉冲触发信号，向所述线激光器阵列发送第一触发信号，根据所述预设曝光时间向所述立体视觉图像传感器发送第二触发信号。
  3. 根据权利要求1所述的系统，其特征在于，所述误差反馈控制器，用于接收所述可编程门阵列FPGA发送的控制信号，输出与所述控制信号对应的指示灯光。
  4. 根据权利要求3所述的系统，其特征在于，所述误差反馈控制器为变色LED灯，包括红、绿、蓝三种基色组合的光。
  5. 根据权利要求1所述的系统，其特征在于，所述立体视觉图像传感器为多目视觉图像传感器，由两个或两个以上的光学相机组成。
  6. 根据权利要求1所述的系统，其特征在于，所述立体视觉传感器中设置有照明装置。
  7. 根据权利要求6所述的系统，其特征在于，所述照明装置的照射时间与所述立体视觉传感器的曝光时间同步。
  8. 根据权利要求1所述的系统，其特征在于，所述线激光器阵列包括由多个线激光器按照矩阵式的排列方式组成。
  9. 根据权利要求1所述的系统，其特征在于，所述上位机，用于对所述特征点进行跟踪，并通过跟踪相邻时间帧间的同名特征点，将不同帧上的激光线配准到同一坐标系中。
  10. 根据权利要求1所述的系统，其特征在于，所述上位机，还用于实时评估所述激光三维扫描设备与被测物体的距离，并在所述距离超出预设距离时，向所述可编程门阵列FPGA反馈评估结果。
  11. 根据权利要求1-10中任一项所述的系统，其特征在于，所述上位机上还设置有通讯接口，所述通讯接口用于向与所述上位机连接的控制设备进行通讯，以使所述控制设备调整所述多线阵列激光三维扫描设备与被测物体间的距离。
  12. 一种基于权利要求1-11中任一项所述的多线阵列激光三维扫描系统的多线阵列激光三维扫描方法，其特征在于，包括：
    所述可编程门阵列FPGA向所述线激光器阵列发送第一触发信号，以使所述线激光阵列根据所述第一触发信号频闪照射被测物体的表面；
    所述可编程门阵列FPGA向所述立体视觉图像传感器发送第二触发信号， 以使所述立体视觉图像传感器根据所述第二触发信号对被测物体进行曝光拍摄，并将拍摄的图像对发送至上位机；
    所述上位机对所述立体视觉图像传感器拍摄的图像对中被测物体的表面反射的激光线进行编码解码；
    所述上位机对所述立体视觉图像传感器拍摄的图像对中被测物体特征点以及所述被测物体的表面反射的激光线进行三维重建；
    所述上位机以所述特征点为基准，将不同帧上的三维激光线数据配准到同一坐标系中生成形面点云；
    所述上位机对测量数据实时进行误差评估并将评估结果反馈至可编程门阵列FPGA；
    所述可编程门阵列FPGA在接收到所述上位机反馈的评估结果后，根据所述评估结果向所述误差反馈控制器发送控制信号，并根据所述评估结果调整所述激光三维扫描设备与被测物体的距离。
  13. 根据权利要求12所述的方法，其特征在于，在所述可编程门阵列FPGA向所述线激光阵列发送第一触发信号之前，所述方法还包括：
    所述可编程门阵列FPGA接收所述上位机发送预设曝光时间以及预设脉冲触发信号，根据所述预设脉冲触发信号向所述线激光阵列发送第一触发信号，根据所述预设曝光时间向所述立体视觉图像传感器发送第二触发信号。
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