WO2020170932A1 - 形状計測システム、及び形状計測方法 - Google Patents
形状計測システム、及び形状計測方法 Download PDFInfo
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- WO2020170932A1 WO2020170932A1 PCT/JP2020/005548 JP2020005548W WO2020170932A1 WO 2020170932 A1 WO2020170932 A1 WO 2020170932A1 JP 2020005548 W JP2020005548 W JP 2020005548W WO 2020170932 A1 WO2020170932 A1 WO 2020170932A1
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- measuring system
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/2441—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures using interferometry
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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
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/026—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness by measuring distance between sensor and object
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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
- G01B11/14—Measuring arrangements characterised by the use of optical techniques for measuring distance or clearance between spaced objects or spaced apertures
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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
- G01B9/00—Measuring instruments characterised by the use of optical techniques
- G01B9/02—Interferometers
- G01B9/0209—Low-coherence interferometers
- G01B9/02091—Tomographic interferometers, e.g. based on optical coherence
Definitions
- the present invention relates to a shape measuring system and a shape measuring method.
- the present invention claims the priority of Japanese Patent Application No. 2019-026172 filed on February 18, 2019, and for the designated countries in which weaving by reference to documents is allowed, the contents described in the application are This application is incorporated by reference.
- the measurement accuracy may deteriorate due to the noise caused by the positional relationship between the measuring device and the object and the measurement environment.
- Patent Document 1 As a countermeasure against this, for example, in Patent Document 1, the same location is measured a plurality of times, locations with high measurement reproducibility are weighted as having high reliability, locations with low measurement reproducibility are weighted as having low reliability, and measurement is performed. A technique for improving the accuracy of measurement data by correcting data based on reliability weighting is disclosed.
- Speckle occurs when irradiating a rough surface with laser light.
- Speckle is a light interference phenomenon that occurs when a coherent light such as a laser light is emitted, and has a characteristic that it occurs at random timing in a statistically determinable place. As described above, the speckles are randomly generated, but the reflection intensity is often strong, and the repeatability is often high. Then, when the rough surface is inclined, a measurement error occurs depending on the beam diameter of the laser light and the inclination angle. Since the measurement error often has high reproducibility, it is difficult to improve the accuracy of the measurement data even if the measurement error is weighted based on the measurement reproducibility as in the technique described in Patent Document 1.
- the present invention has been made in view of such a situation, and an object thereof is to enable the shape of an object to be measured with high accuracy.
- the present application includes a plurality of means for solving at least a part of the above problems, and the examples are as follows.
- a shape measuring system provides a distance measuring head that irradiates an object with light and receives reflected light from the object, and distance detection based on the reflected light.
- a distance measuring device that generates a waveform, and a control device that analyzes the distance detection waveform to calculate a measured distance value to the object, the control device calculating a feature amount of the distance detection waveform.
- One of the features is that one is performed.
- FIG. 1 is a diagram showing a configuration example of a shape measuring system according to an embodiment of the present invention.
- FIG. 2 is a diagram for explaining the principle of the FMCW (Frequency Modulated Continuous Wave) system.
- FIG. 3 is a diagram showing an example of a distance detection waveform of the FMCW method.
- FIG. 4 is a diagram showing a configuration example of the distance measuring head.
- FIG. 5 is a diagram showing a configuration example of the scanning mechanism.
- FIG. 6 is a diagram showing an example of a distance measurement result with respect to a smooth inclined surface.
- FIG. 7 is a figure which shows an example of the distance measurement result with respect to a rough inclined surface.
- FIG. 1 is a diagram showing a configuration example of a shape measuring system according to an embodiment of the present invention.
- FIG. 2 is a diagram for explaining the principle of the FMCW (Frequency Modulated Continuous Wave) system.
- FIG. 3 is a diagram showing an example of a distance detection waveform of
- FIG. 8 is a diagram showing an example of a distance measurement result obtained when a beam is scanned on a rough inclined surface for measurement.
- FIG. 9 is a diagram for explaining a method of coping with an error in the measured distance value due to speckle 1.
- FIG. 10 is a diagram for explaining an example of a method of calculating a feature amount from a distance detection waveform based on a statistic.
- FIG. 11 is a diagram for explaining an example of a method of calculating a feature amount by waveform fitting.
- FIG. 12 is a diagram showing an example of a distance measurement result for a smooth curved surface.
- FIG. 13 is a figure which shows an example of the distance measurement result with respect to a rough curved surface.
- FIG. 14 is a flowchart illustrating an example of the first process performed by the control device.
- FIG. 15 is a diagram illustrating a hardware configuration example of the distance measuring device.
- FIG. 16 is a diagram showing a display example of a GUI (Graphical User Interface) screen corresponding to the first processing.
- FIG. 17 is a flowchart illustrating a modified example of the first process.
- FIG. 18 is a diagram for explaining step S11 of FIG.
- FIG. 19 is a diagram showing a display example of a GUI screen corresponding to the modification of FIG.
- FIG. 20 is a flowchart illustrating an example of the second process performed by the control device.
- FIG. 21 is a diagram for explaining an example of a method of calculating the feature amount from the distance detection waveform when the inclination angle of the object is known.
- FIG. 22 is a diagram for explaining an example of a method of obtaining the tilt angle, curvature, and roughness of the object based on the CAD data.
- FIG. 23 is a diagram showing a display example of a GUI screen corresponding to the second processing.
- FIG. 24 is a flowchart for explaining the third processing by the control device.
- FIG. 25 is a diagram for explaining an example of a method of calculating the step position.
- FIG. 26 is a diagram for explaining the relationship between the speckle position and the distance detection waveform when measuring the rough surface/slope surface.
- FIG. 27 is a diagram showing the concept of extracting highly reliable points using the continuity of detected waveform peak intensities.
- FIG. 28 is a diagram for explaining an optical disconnection method that can replace the FMCW method.
- FIG. 1 shows a configuration example of a shape measuring system 1 according to an embodiment of the present invention.
- the shape measuring system 1 adopts an FMCW (Frequency Modulated Continuous Wave) method as a distance measuring method.
- the shape measuring system 1 includes a distance measuring device 100, a distance measuring head 117, a control device 119, a display device 120, and a scanning mechanism 500 (FIG. 5).
- the distance measurement control unit 116 transmits a sweep waveform signal to the oscillator 102.
- the oscillator 102 injects a triangular wave current into the laser light source 101 to modulate a drive current.
- the laser light source 101 generates FM (Frequency Modulated) light whose frequency is swept with time at a constant modulation speed.
- the laser light source 101 may be configured by a semiconductor laser device with an external resonator, and the resonance wavelength of the laser light source 101 may be changed by a triangular wave control signal from the oscillator 102. In this case, the laser light source 101 generates FM light whose frequency is swept in time.
- FM light (hereinafter, simply referred to as light) generated by the laser light source 101 is guided to the optical fiber coupler 103.
- the optical fiber coupler 103 splits the guided light into two.
- the optical fiber couplers 103, 104, 106, 111 may be beam splitters.
- the optical fiber coupler 104 further divides the light into two.
- One of the light beams split by the optical fiber coupler 104 is provided with a constant optical path difference by the optical fiber 105, and then the other of the light beams split by the optical fiber coupler 104 by the optical fiber coupler 106.
- the light is multiplexed and guided to the light receiver 107.
- the light receiver 107 is composed of a Mach-Zehnder interferometer.
- the light receiver 107 detects a constant reference beat signal proportional to the optical path difference of the combined light, and outputs it to the distance measurement control unit 116.
- the other half of the light split by the optical fiber coupler 103 passes through the circulator 108 and is branched by the optical fiber coupler 111.
- One of the lights branched by the optical fiber coupler 111 is reflected by the reference mirror 112 and becomes reference light.
- One of the lights branched by the optical fiber coupler 111 passes through the connection cable 118 as measurement light, is guided to the distance measuring head 117, is emitted into space by the optical fiber collimator 113, and is beam-scanned by the beam scanning mechanism 114. , The object 115 is irradiated.
- the reflected light reflected by the object 115 passes through the beam scanning mechanism 114 and the optical fiber collimator 113 again, is combined with the reference light reflected by the reference mirror 112 by the optical fiber coupler 111, and is received by the circulator 108 as a light receiver. The light is guided to 109.
- the light receiver 109 is composed of a Mach-Zehnder interferometer.
- the light receiver 109 detects the measurement beat signal generated by the interference between the reference light and the reflected light, and outputs it to the distance measurement control unit 116.
- the distance measurement control unit 116 A/D converts the measurement beat signal from the light receiver 109 using the reference beat signal from the light receiver 107 as a sampling clock.
- the distance measurement control unit 116 samples the reference beat signal and the measurement beat signal with a constant sampling clock. That is, the reference beat signal can be generated as a signal with a 90-degree phase shift by performing the Hilbert transform, and the local phase of the signal can be obtained from the reference signals before and after the Hilbert transform. By interpolating the phase, the timing when the reference signal has a constant phase can be obtained. By interpolating and sampling the measurement beat signal at this timing, the measurement signal can be resampled with the reference signal as a reference.
- the distance measurement control unit 116 has the same effect even when the AD/DA converter incorporated therein samples the measurement signal by using the reference beat signal as a sampling clock and performs A/D conversion.
- the distance measurement control unit 116 analyzes the beat signal using the FMCW method as the distance measurement method, and transmits the distance measurement data obtained as a result to the control device 119.
- the distance measuring head 117 may include the distance measuring device 100 and the control device 119. Further, the control device 119 may be included in the distance measuring device 100.
- FIG. 2 is a diagram for explaining the principle of the FMCW method.
- the photodetector 109 detects a beat signal having a beat frequency fb equal to this frequency difference. If the frequency sweep width is ⁇ and the time required to modulate by ⁇ is T, the following equation (1) holds.
- the distance L to the object 115 is half the distance that light travels during the time difference ⁇ t. Therefore, the distance L can be calculated by the following equation (2) using the light velocity c in the atmosphere.
- the distance L and the beat frequency fb have a linear relationship. Therefore, if the FFT (First Fourier Transform) is performed on the measurement signal obtained by the light receiver 109 and the peak position and the magnitude are obtained, the reflection position and the amount of reflected light of the object 115 can be obtained.
- FFT First Fourier Transform
- FIG. 3 is a diagram for explaining a method for obtaining the reflection position on the surface of the object 115 from the reflection intensity profile, and shows an example of the distance detection waveform of the FMCW method.
- the horizontal axis represents the FFT frequency axis and the vertical axis represents the reflection intensity.
- the vicinity of the peak point of the distance detection waveform 301 is discrete data.
- the peak width w is calculated by the distance resolution c/2 ⁇ .
- a function such as a quadratic function or a Gaussian function is applied using data of three or more points near the peak point, and when the peak of the applied function is used, the position of the measurement target can be determined with accuracy higher than the distance resolution. It is possible to ask.
- FFT is given as an example of the beat frequency analysis
- the maximum entropy method may be used for the beat frequency analysis, for example.
- the peak position can be detected with higher resolution than FFT.
- the distance measurement control unit 116 uses the FMCW method as the distance measurement method, but adopts other light propagation time measurement methods such as OCT (Optical Coherence Tomography) and TOF (Time OF Flight). May be.
- OCT Optical Coherence Tomography
- TOF Time OF Flight
- FIG. 4 shows a configuration example of the distance measuring head 117.
- the distance measuring head 117 emits the measurement light supplied from the distance measuring device 100 via the connection cable 118 to the space by the optical fiber collimator 113, and deflects the emitted light by the optical path switching element 407 corresponding to the beam scanning mechanism 114. Then, the target object 115 is irradiated.
- the optical path switching element 407 is held by the probe tip portion 406, and the probe tip portion 406 is held by the rotating mechanism 405.
- the rotating mechanism 405 rotates
- the optical path switching element 407 rotates and the object 115. It becomes possible to measure the cross-sectional shape of the.
- the distance measurement data and the rotation angle information of the rotary motor are used.
- the beam scanning mechanism 114 may scan a beam using a galvanometer mirror.
- the measurement light can be scanned one-dimensionally
- two galvanometer mirrors are used, the measurement light can be scanned two-dimensionally.
- the beam scanning mechanism 114 another mechanism capable of deflecting light such as a MEMS mirror or a polygon mirror and capable of scanning may be used for scanning.
- Information such as the length of the probe tip 406, the deflection angle of the beam, and the beam scanning angle is input to the distance measurement control unit 116 of the distance measurement device 100 from the distance measurement head 117. These pieces of information are used when the distance measurement control unit 116 generates the three-dimensional shape point cloud of the object 115.
- FIG. 5 shows a configuration example of a scanning mechanism 500 for three-dimensionally scanning the distance measuring head 117.
- the scanning mechanism 500 is for moving the distance measuring head 117 on a gantry stage to measure the shape of the object 115.
- the gate-type scanning mechanism 500 has an X-axis moving mechanism 502 that moves in the X-axis direction mounted on a Y-axis moving mechanism 501 that moves in the Y-axis direction.
- a Z-axis moving mechanism 503 that moves to is mounted. Accordingly, the scanning mechanism 500 can move the distance measuring head 117 three-dimensionally around the object 115.
- the Y-axis moving mechanism 501, the X-axis moving mechanism 502, and the Z-axis moving mechanism 503 are driven under the control of the control device 119 to scan the distance measuring head 117 in three dimensions.
- the distance measuring head 117 by scanning the distance measuring head 117 with the scanning mechanism 500, it is possible to realize highly functional non-contact shape measurement.
- the object 115 is small and the shape can be measured only by moving in the Z-axis direction, the object 115 is positioned by a jig so that the position is uniquely determined, and only the Z-axis moving mechanism 503 is moved to perform measurement. You may.
- the distance measuring head 117 may be scanned using a general 3-axis processing machine without using the scanning mechanism 500.
- the Z-axis is often provided on the tool side and the X-axis and the Y-axis are provided on the object side in the three-axis processing machine. It becomes possible to realize on-machine measurement. Further, the multi-degree-of-freedom robot may hold and move the distance measuring head 117.
- FIG. 6 shows an example of distance measurement results when the surface of the object 115 is a smooth inclined surface.
- the intensity distribution of the laser 601 that irradiates the object 115 is a Gaussian distribution
- the beam diameter at the object 115 is D.
- the laser 601 is applied to the inclined surface 604 (inclination angle ⁇ ) of the object 115, a distance difference of D ⁇ sin ⁇ is generated in the beam irradiation region.
- the detected distance detection waveform 602 has a Gaussian distribution shape with a foot width of D ⁇ sin ⁇ .
- the distance detection waveform 602 obtained by convolving the distance resolution and the Gaussian distribution shown in FIG. 3 is obtained.
- the peak point 603 of the distance detection waveform 602 becomes the center of the Gaussian distribution, and the value on the distance axis of the detected peak point 603 becomes the distance measurement value.
- FIG. 7 shows an example of distance measurement results when the surface of the object 115 is a rough inclined surface.
- speckle is a light interference phenomenon that occurs when irradiating coherent light such as a laser. The location where it occurs is statistically determined and occurs at random timing, with the characteristic that the reflection intensity is partially strong. Have.
- the laser 601 strongly detects the speckle intensity 705 at the left end of the rough inclined surface 704 of the object 115.
- the distance detection waveform 702 is detected and has a different shape from the distance detection waveform 602 of the Gaussian distribution shown in FIG.
- the peak point 703 is the end of the width of the foot of the distance detection waveform 702 and deviates from the peak point 603 shown in FIG. 6, so that an error occurs in the distance measurement value.
- FIG. 8 shows an example of the distance measurement result when the laser 601 scans the rough inclined surface 704 of the object 115.
- the laser 601 irradiates the inclined surface 704 and the intensity of the reflected light due to speckles at a certain position is high, that position is detected as a peak point, and the peak point becomes the distance measurement value.
- the laser 601 is scanned to measure the distance at the next position of the inclined surface 704. Since the laser 601 has the beam diameter D, the speckle detected earlier may be irradiated with the laser 601. , In that case, the reflected light intensity due to the speckle becomes strong again, and the point is detected again as the peak point, and the position at the peak point becomes the distance measurement value corresponding to the beam position after scanning. End up.
- the distance measurement value of the previous time and the distance measurement value of this time should be different from each other, but a certain speckle is irradiated with the laser 601. During this period, a phenomenon occurs in which the distance measurement value does not change. Then, when the laser 601 deviates from the speckle, a peak point is detected for the next dominant speckle, and as a result, as shown in FIG. The distance measurement value of is obtained. However, since speckles are statistically generated, the distance measurement value is not always stepwise.
- Fig. 9 shows the concept of how to deal with the error in the measured distance value due to speckle.
- the error in the measured distance value due to the speckle occurs because the distance detection waveform is distorted depending on the position where the speckle occurs.
- the error of the measured distance value increases as the distortion of the distance detection waveform increases. Therefore, the feature amount of the shape of the distance detection waveform is calculated, and based on the calculated feature amount, at least one of the correction process of the measured distance value and the reliability weighting process is performed.
- FIG. 10 is a diagram for explaining the process of calculating the feature amount from the distance detection waveform.
- a method of using the skewness as the feature amount of the distance detection waveform will be described.
- the number of points constituting the distance detection waveform is n
- the distance between the points is x i
- the detection intensity is p i
- the average distance is x a
- the standard deviation is ⁇
- the skewness S can be obtained by the following equation (3) (feature amount calculation equation).
- the correction amount C can be obtained by multiplying the obtained cube root of the skewness S by the coefficient ⁇ .
- the coefficient ⁇ may be determined based on experiments, or based on an optical simulation that models speckle generation.
- Formula (4) is an example of a correction formula for obtaining the correction amount C, and a formula other than formula (4) may be used as the correction formula.
- the reliability weighting amount w can be obtained by multiplying the obtained skewness S by the coefficient ⁇ .
- the coefficient ⁇ may be determined based on an experiment, or may be determined based on an optical simulation that models speckle generation.
- the expression (5) is an example of the reliability weighting expression, and a mathematical expression other than the expression (5) may be used as the reliability weighting expression.
- the skewness S is calculated as the feature quantity of the distance detection waveform, but the feature quantity is not limited to the skewness S.
- a statistical amount such as variance or kurtosis may be calculated as the feature amount.
- waveform fitting may be used as another method of calculating the feature amount.
- the reflection intensity at a certain position becomes strong, so that the distance detection waveform is distorted.
- the shape of the detected waveform has a distribution in which reflected lights from a plurality of places are superposed. Therefore, by fitting using a plurality of waveforms, a waveform most similar to the distance detection waveform can be calculated.
- FIG. 11 is a diagram for explaining a feature amount calculation method using waveform fitting.
- two waveforms 1101 and 1102 represented by broken lines are fitted to the distance detection waveform 702 represented by a solid line, but the number of waveforms used for fitting is not limited to two, but two or more. Good.
- the fitting parameters are the center coordinates of the waveforms 1101 and 1102, the peak value, the variance, and the phase.
- the values of the parameters of the waveforms 1101 and 1102 are determined so as to best fit the distance detection waveform 702.
- the determined parameter is used as a feature amount, and the correction amount or the reliability weighting amount is determined using this feature amount.
- the coordinate x3 which is an intermediate value thereof may be used as the correction value.
- the difference x3-x between the coordinate x3 and the coordinate x of the peak point 1103 of the distance detection waveform 702 may be used as the reliability weighting amount.
- FIG. 12 shows an example of distance measurement results when the surface of the object 115 is a smooth curved surface.
- the intensity of reflected light from the curved surface 1203 of the object 115 is uniform and the curved surface 1203 is irradiated with a laser 601 having a predetermined beam diameter.
- the normal vector of the curved surface 1203 differs depending on the irradiation position of the laser 601
- the normal vector 1201 of the curved surface on the left side of the laser 601 faces the beam irradiation direction
- the normal vector 1202 of the curved surface on the right side of the laser 601. Has an inclination to the right with respect to the beam irradiation direction.
- the distance detection waveform 1205 has a shape in which the Gaussian distribution is distorted, and the peak point 1206 is detected closer to the beam center position. Furthermore, when the laser 601 is scanned on the curved surface 1203 to measure the distance, a peak point is detected at each measurement position on the short distance side with respect to the beam center position. As a result, a curve (distance measurement value) 1204 having a larger radius of curvature than the actual curved surface 1203 will be measured.
- FIG. 13 shows an example of distance measurement results when the surface of the object 115 is a rough curved surface.
- a stepwise error due to speckle occurs as in the case shown in FIG. 7.
- a curve (distance measurement value) 1302 having a larger radius of curvature than the actual curved surface 1301 and having a stepwise error is measured.
- the distance error that occurs when the curved surface of the object 115 is measured is also due to the distortion of the shape of the distance detection waveform, similar to the distance error that occurs when measuring the inclined surface described above. Therefore, also for the correction or the reliability weighting for the curved surface, the parameter obtained by the correction or the reliability weighting using the skewness as the feature amount described with reference to FIG. 10 or the waveform fitting described with reference to FIG. It is possible to apply the correction or the reliability weighting with the feature amount as.
- FIG. 14 shows an example of a first process performed by the control device 119 for coping with a distance measurement error caused by speckle.
- the first process is to perform at least one of a correction process and a process of weighting the measurement point group with reliability as a measure against a distance measurement error caused by speckle.
- the input information 1400 includes distance measurement information 1403, distance measurement head scanning mechanism information 1404, correction parameters 1405, and reliability weighting parameters 1406.
- the distance measurement information 1403 is distance measurement data (distance detection waveform) measured by the distance measurement device 100 described with reference to FIG. 1, rotation angle data of the rotation mechanism 405 (FIG. 4), and the like.
- the distance measurement data may be all the data of the FFT result with respect to the beat frequency, or when the data amount is large, the peak detected point and the data for n points before and after the point.
- n is the number of points required to characterize the distance detection waveform, and is determined in advance by experiment or by optical simulation. n may be a fixed value or may be changeable as a parameter.
- the correction parameter 1405 and the reliability weighting parameter 1406 are parameters necessary for performing the correction or reliability weighting described below.
- the control device 119 acquires a distance detection waveform from the distance measurement device 100 (step S1), and then calculates a feature amount from the distance detection waveform (step S2).
- the control device 119 performs at least one of a process of inputting and correcting the characteristic amount in the correction formula and a process of inputting the characteristic amount in the reliability weighting formula and weighting the reliability (step S3). At this time, it is possible to adjust the correction amount and the reliability weighting amount by using the correction parameter 1405 or the reliability weighting parameter 1406.
- control device 119 causes the reliability weighted distance obtained in step S3, the scanning coordinates of the distance measuring head 117 as the distance measuring head scanning mechanism information 1404, and the rotation angle of the rotating mechanism 405 as the distance measuring information 1403. Reliability-weighted three-dimensional point group coordinates are calculated based on the data and the like (step S4). Then, the control device 119 outputs the reliability-weighted point group 1411 as the output information 1402.
- FIG. 15 shows an example of the hardware configuration of the control device 119.
- the control device 119 includes, for example, a general computer, and includes a CPU (Central Processing Unit) 1501, a memory 1502, and a storage device 1503.
- the CPU 1501 executes the predetermined program loaded in the memory 1502 to execute the first process shown in FIG.
- the memory 1502 holds the above-mentioned programs and data in the process of processing.
- the storage device 1503 stores a feature amount calculation formula, a correction formula, a reliability weighting formula, and the like in the storage device 1503.
- FIG. 16 shows a display example of the GUI screen 1600 displayed on the display device 120 by the first processing.
- the GUI screen 1600 is provided with a distance measurement information display field 1601, a distance measurement head scanning mechanism information display field 1602, a correction parameter display field 1603, a reliability weighting parameter display field 1604, and a reliability weighted point group display field 1605. ing.
- the identification information of the distance measuring head 117 is displayed in the distance measurement information display field 1601.
- Identification information of the scanning mechanism 500 is displayed in the distance measurement head scanning mechanism information display field 1602.
- the correction parameter display field 1603 allows the user to input and set correction parameters.
- the reliability weighting parameter display field 1604 allows the user to input and set reliability weighting parameters.
- the reliability weighted point group display field 1605 displays the reliability weighted point group.
- the user can change the correction parameter or the reliability weighting parameter by looking at the reliability weighted point cloud displayed in the reliability weighted point cloud display field 1605.
- FIG. 17 is a flowchart showing a modification of the first processing.
- point cloud processing steps S11 and S12
- FIG. 14 is added to the first processing (FIG. 14).
- the noise removal parameter 1703 and the fitting parameter 1704 are input as the input information 1700 in addition to the reliability weighted point group 1411 which is the result of the first processing, and the control device 119 sets the reliability weighted Noise removal and fitting are performed on the point group 1411 (step S11).
- the control device 119 outputs the three-dimensional shape data 1707 obtained as a result of step S11 as output information 1702 (step S12).
- FIG. 18 illustrates a process of calculating the shape of the reliability weighted point group 1411 by noise removal and fitting in step S11.
- step S11 points with low reliability in the reliability-weighted point group 1411 measured by the distance measuring head 117 are likely to be out of the true shape, and thus are determined to be noise and are removed. .. Then, the remaining points that have not been removed are fitted based on the reliability weighting amount.
- fitting it is possible to use polygons to form a surface. By forming polygons according to the weight of reliability, the three-dimensional shape 1800 can be calculated accurately.
- the polygon may be a triangle or a quadrangle, but may be a polygon having more than that.
- FIG. 19 shows a display example of a GUI screen 1900 displayed on the display device 120 according to a modification of the first processing.
- the GUI screen 1900 has a noise removal parameter setting field 1901, a fitting parameter setting field 1902, and a three-dimensional shape data display field 1903 added to the GUI screen 1600 (FIG. 16).
- the user can input and set the noise removal parameter in the noise removal parameter setting field 1901.
- the fitting parameter setting field 1902 allows the user to input and set fitting parameters.
- the user can change the noise removal parameter or the fitting parameter by viewing the 3D shape data displayed in the 3D shape data display field 1903.
- the distance is calculated from the interference beat frequency of the reference light and the measurement light.
- the phase of the reference light and the measurement light is phase-adjusted due to the surface roughness. If the deviation occurs, the beat frequency may change, which may cause an error in the measurement distance. However, even if an error occurs, the continuity of the measurement points may reduce the error due to the roughness.
- the irradiation angle and the radius of curvature of the target object 115 can be obtained from the position and orientation of the distance measuring head 117 with respect to the target object 115. Do at least one of the.
- the irradiation angle and the radius of curvature of the object 115 are known, there is a possibility that the accuracy can be further improved and correction or reliability weighting can be performed. Further, by adding the roughness information of the surface of the object 115, it may be possible to perform the correction or the reliability weighting with higher accuracy. If the roughness information is attached to the CAD data, the information is used. If it is not attached to the CAD data, the user may input the roughness information on the GUI screen.
- FIG. 20 is a flowchart illustrating an example of the second process performed by the control device 119.
- the input information 2000 for the second processing is obtained by adding the object CAD information 2001, the object roughness information 2002, and the distance measurement head position/orientation information 2003 to the input information 1400 (FIG. 14).
- the control device 119 determines the relative position between the object 115 and the distance measuring head 117 (step S21). Next, the control device 119 obtains the tilt angle, the radius of curvature, and the roughness of the object 115 with respect to the irradiation light from the object CAD information 2001 and the position/orientation information 2003 of the distance measuring head (step S22). Next, the control device 119 acquires the distance detection waveform from the distance measuring device 100 (step S23). Next, the control device 119 calculates a feature amount from the distance measurement waveform based on the tilt angle, the radius of curvature, and the roughness of the target object 115 obtained in step S22 (step S24).
- control device 119 executes at least one of a process of inputting and correcting the characteristic amount in the correction formula and a process of inputting the characteristic amount in the reliability weighting formula and weighting the reliability (step S25).
- control device 119 determines the reliability based on the distance measurement head scanning mechanism information 1404, the rotation angle of the rotation mechanism 405 as the distance measurement information 1403, and the reliability weighted distance obtained in step S25.
- a weighted three-dimensional point group is calculated (step S26).
- control device 119 outputs, as the output information 2004, the CAD information 2010 to which the information on the inclination angle, the radius of curvature, and the roughness of the object 115 with respect to the irradiation light is added, and the reliability-weighted point group 2011.
- noise removal or fitting is performed by using the output point group 2011 with weighted reliability, and the shape is calculated with high accuracy. It can be modified as possible.
- FIG. 21 is a diagram for explaining an example of a correction or reliability weighting method when the inclination angle of the slope of the object 115 is known in advance based on the CAD data.
- the distance difference D ⁇ sin ⁇ can be calculated from the beam diameter D.
- the base width 2101 of the peak of the distance detection waveform 702 can be known, and the base width 2101 of the peak can be used as the feature amount, and for example, the central position 2100 can be corrected as the peak point.
- the difference xc ⁇ x between the coordinate xc of the peak point and the peak coordinate x of the distance detection waveform 702 may be used as the reliability weighting amount.
- the correction method or the reliability weighting method shown in FIG. 21 is an example, and another method may be used.
- FIG. 22 is a diagram for explaining a method for obtaining the inclination angle, the radius of curvature, and the roughness of the object 115 based on the CAD data and the relative position of the object 115 and the distance measuring head 117. is there.
- the incident angle of the beam emitted from the distance measuring head 117 to the object 115 should be geometrically calculated by the control device 119 based on the CAD data of the object 115 and the position/orientation of the distance measuring head 117. It is possible to obtain the tilt angle and the radius of curvature of the measurement target with respect to the irradiation light.
- the control device 119 adds the calculation results of the tilt angle, the radius of curvature, and the roughness to the object CAD information 2001.
- FIG. 23 shows a display example of the GUI screen 2300 displayed on the display device 120 by the second processing.
- the GUI screen 2300 is different from the GUI screen 1600 (FIG. 16) in the object CAD information display field 2301, the object roughness information display field 2302, the distance measurement head position/orientation display field 2303, and the object inclination angle.
- a curvature radius and roughness display column 2304 is added.
- the acquisition destination (file path) of the target CAD information is displayed.
- the acquisition destination (file path) of the object roughness information is displayed.
- the acquisition destination (file path) of the position/orientation information of the distance measuring head is displayed.
- CAD data to which the tilt angle, the curvature radius, and the roughness of the target object 115 are added is displayed in the target object tilt angle, the curvature radius, and the roughness display field 2304.
- the inclination angle, the curvature, and the roughness of the measurement area of the object 115 are obtained based on the continuity of the distance measurement data, and the accuracy is improved based on these. At least one of correction and reliability weighting is performed.
- FIG. 24 is a flowchart illustrating an example of the third processing by the control device 119.
- the input information 1400 for the third process is the same as the input information 1400 for the first process (FIG. 14).
- the control device 119 acquires a distance detection waveform from the distance measurement information 1403 (step S31), and then calculates a feature amount from the distance detection waveform (step S32).
- the control device 119 performs at least one of a process of inputting and correcting the characteristic amount in the correction formula and a process of inputting the characteristic amount in the reliability weighting formula and weighting the reliability (step S33). At this time, it is possible to adjust the correction amount and the reliability weighting amount by using the correction parameter 1405 or the reliability weighting parameter 1406.
- control device 119 causes the scanning coordinates of the distance measuring head 117 as the distance measuring head scanning mechanism information 1404, the rotation angle data of the rotating mechanism 405 as the distance measuring information 1403, and the reliability weight obtained in step S33. Reliability-weighted three-dimensional point group coordinates are calculated based on the attached distance (step S34).
- control device 119 calculates the tilt angle, the radius of curvature, and the roughness of the measurement target region from the continuity of the measurement point group (step S35).
- control device 119 again calculates the feature amount from the distance detection waveform based on the information on the tilt angle, the radius of curvature, and the roughness calculated in step S35 (step S36).
- control device 119 performs at least one of a process of inputting and correcting the feature amount in the correction formula and a process of inputting the feature amount in the reliability weighting formula and weighting the reliability (step S37). At this time, it is possible to adjust the correction amount and the reliability weighting amount by using the correction parameter 1405 or the reliability weighting parameter 1406.
- control device 119 weights the reliability based on the scanning coordinates of the distance measuring head 117, the rotation angle data of the rotating mechanism 405 as the distance measurement information 1403, and the reliability-weighted distance obtained in step S37.
- the calculated three-dimensional point group coordinates are calculated (step S38).
- the control device 119 outputs the reliability-weighted point group 1411 as the output information 1402.
- noise removal or fitting is performed by using the output point group 2011 with weighted reliability, and the shape is calculated with high accuracy. It can be modified as possible.
- FIG. 25 is a diagram for explaining a method of accurately obtaining the step 2501 of the object 115.
- the reflected light from the upper surface and the reflected light from the lower surface of the step 2501 are detected at the same time, so that two detection peaks are detected.
- the edge of the step is obtained from the distance detection waveform obtained when the laser 601 is scanned.
- the laser 601 is scanned to the right, and when the center of the laser 601 is at a step, the reflected light intensities 2502 and 2503 from the upper surface and the lower surface become equal.
- the laser 601 is scanned rightward and the center of the laser 601 exceeds the step 2501, the reflected light intensity 2502 from the upper surface becomes weaker and the reflected light intensity 2503 from the lower surface becomes stronger.
- the position of the step 2501 can be calculated with high accuracy.
- the positions where the intensity ratios are equal to each other may be obtained by interpolation from the results of front and rear scanning.
- the point where the reflected light intensity from the upper surface and the lower surface are equal does not become the step position.
- the strength of the reflected light intensity of the upper surface is obtained from the reflected light intensity 2502 from the upper surface obtained when the entire laser 601 is in front of the step 2501, and obtained when the entire laser 601 exceeds the step 2501.
- the intensity of the reflected light intensity of the lower surface is calculated from the reflected light intensity 2503 from the lower surface, the difference in reflectance is calculated from the ratio, and then the position of the step 2501 may be determined.
- the height of the step 2501 is increased, a part of the reflected light from the lower surface is blocked by the step 2501, so that the amount of reflected light may be reduced.
- the attenuation amount is geometrically determined by the incident angle of the laser 601 and the step distance. Therefore, the height of the step is calculated from the measured distance difference between the upper surface and the lower surface, and the attenuation value is calculated.
- the position of the step 2501 may be calculated from the reflected light amount ratio of the upper surface and the lower surface in consideration.
- the peak intensity information of the distance detection waveform may be used as the feature amount of the distance detection waveform.
- FIG. 26 is a diagram for explaining the relationship between the speckle position and the distance detection waveform when measuring a rough surface/slope surface.
- the irradiation beam 601 has a Gaussian distribution, and if speckle occurs at the end of the beam, the detected waveform is distorted as shown by 2701 and the detection intensity becomes weak.
- the distortion is reduced and the detection intensity is increased as indicated by the detection waveform 2702.
- the detected waveform is distorted again as shown by 2703 and the detected intensity is weakened. Therefore, by using the continuity of the detected waveform peak intensity, points with high reliability are extracted.
- FIG. 27 shows the concept of extracting highly reliable points by using the continuity of the detected waveform peak intensities.
- the distance measurement result obtained by scanning the beam on the rough surface / inclined surface is stepwise.
- the staircase period depends on the beam spot size.
- the detected waveform peak intensities obtained at this time are plotted, it has a distribution corresponding to the period of the stairs.
- the speckle is at the edge of the beam, the intensity becomes weak, when the spec is located at the beam center, the intensity becomes a maximum value, and when the speckle deviates from the beam center, the intensity becomes weak. Therefore, by extracting the point where the intensity has the maximum value, it is possible to reduce the measurement error and obtain the actual shape with high accuracy.
- the peak may be accurately obtained by Gaussian fitting.
- the reliability may be weighted using intensity information.
- the intensity maximum value and the intensity minimum value are obtained from the continuity of the peak intensity, the weight of the point corresponding to the maximum value is set to be the highest, and the weight of the point corresponding to the minimum value is set to the highest.
- the weight is lightened, and the points in between are weighted between the maximum value and the minimum value by interpolation based on the peak intensity.
- interpolation for example, linear interpolation is used.
- the weighted point group can perform noise removal or fitting by using the output reliability weighted point group to calculate the shape with high accuracy, as in the modified example of the first processing (FIG. 17). it can.
- the error can be further reduced. It is possible.
- the feature amount of the distance detection waveform is detected using skewness, kurtosis, and fitting, but it may be detected using the center of gravity.
- FIG. 28 is a diagram for explaining an optical disconnection method that can replace the FMCW method.
- the object 115 is irradiated with the linear beam 2601 from the light source 2600.
- a light-section line 2604 along the shape of the target object 115 is formed in the obtained image.
- the shape of the object 115 can be calculated from the light section line 2604.
- the intensity profile of the line-shaped beam 2601 has a Gaussian distribution 2605, and normally, the intensity of the light cutting line 2604 also has a Gaussian distribution.
- the distance detection waveform 2606 is distorted, and the peak point may be erroneously detected, causing an error in the measured distance.
- the shape of the target object 115 is accurately calculated. It becomes possible to do.
- the present invention is not limited to the examples of the above-described embodiments, and various modifications are included.
- the above-described example of the embodiment is described in detail for making the present invention easy to understand, and the present invention is not limited to one including all the configurations described herein.
- a part of the configuration of the example of each embodiment may be added, deleted, or replaced with another configuration.
- control lines and information lines in the figure show those which are considered necessary for explanation, and not all of them are shown. It may be considered that almost all configurations are connected to each other.
- the configuration of the above distance measurement system can be classified into more components according to the processing content. Also, one component can be classified so as to perform more processing.
- Shape measuring system 100... Distance measuring device, 101... Laser light source, 102... Oscillator, 103... Optical fiber coupler, 104... Optical fiber coupler, 105... Optical Fiber, 106... Optical fiber coupler, 107... Optical receiver, 108... Circulator, 109... Optical receiver, 111... Optical fiber coupler, 112... Reference mirror, 113... Optical Fiber collimator, 114... Beam scanning mechanism, 115... Object, 116... Distance measurement control unit, 117... Distance measurement head, 118... Connection cable, 119... Control device, 120 ... Display device, 201... Reference light, 202... Measurement signal, 301... Distance detection waveform, 405...
- Input information 1402... Output information, 1403... Distance measurement information, 1404...
- Distance measurement head scanning mechanism information 1405... Correction parameter 1406... Reliability weighting parameter, 1411... Reliability weighted point group, 1501... CPU, 1502... Memory, 1503... Storage device, 1600... GUI screen, 1601... Distance measurement information display field, 1602... Distance measurement head scanning mechanism information display field, 1603... Correction parameter display field, 1604... Reliability weighting parameter display field, 1605... Reliability weighted point cloud Display column, 1700... Input information, 1702... Output information, 1703... Noise removal parameter, 1704... Fitting parameter, 1900... GUI screen, 1901... Noise removal parameter setting column, 1902 ... Fitting parameter setting field, 2000...
- Input information 200 1... Target CAD information, 2002... Target roughness information, 2003... Distance measuring head position/posture information, 2004... Output information, 2010... CAD information, 2011... Reliability Degree-weighted point group, 2100... central position, 2101... foot width, 2300... GUI screen, 2301... object CAD information display column, 2302... object roughness information display column, 2303... Distance measurement head position/posture display field, 2304... Roughness display field, 2501... Step, 2502... Reflected light intensity, 2503... Reflected light intensity, 2600... Light source , 2601... Line beam, 2603... Camera, 2604... Light section line, 2605... Gaussian distribution, 2606... Distance detection waveform, c... Distance resolution
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Abstract
Description
図1は、本発明の一実施の形態に係る形状計測システム1の構成例を示している。該形状計測システム1は、距離計測方式としてFMCW(Frequency Modulated Continuous Wave)方式を採用する。形状計測システム1は、距離計測装置100、距離計測ヘッド117、制御装置119、表示装置120、及び走査機構500(図5)を備える。
次に、対象物115の表面が傾斜面である場合の距離計測結果について、図6~図8を参照して説明する。
次に、対象物115の粗い傾斜面にて発生し得るスペックル起因の計測距離値の誤差への対処方法について説明する。本実施形態では、該対処方法としては、測定距離値の補正処理、及び信頼性重み付け処理の少なくとも一方を行う。
次に、対象物115の表面が曲面である場合の距離計測結果について、図12及び図13を参照して説明する。
次に、図14は、スペックル起因の距離計測誤差に対処するための制御装置119による第1の処理の一例を示している。該第1の処理は、スペックル起因の距離計測誤差への対処として、補正処理、及び計測点群に対して信頼度重み付けをする処理の少なくとも一方を行うものである。
次に、図17は、第1の処理の変形例を示すフローチャートである。該変形例は、第1の処理(図14)に対して点群処理(ステップS11,S12)を追加したものである。
次に、対象物115のCAD(Computer Aided Design)データを制御装置119が取得できる場合に実行可能な第2の処理について説明する。
次に、制御装置119による第3の処理について説明する。
次に、図25は、対象物115が有する段差2501を精度良く求める方法について説明するための図である。対象物115の段差2501を計測する場合、段差2501の上面からの反射光と下面からの反射光とが同時に検出されるため、検出ピークが2箇所検出される。
距離検出波形の特徴量として、距離検出波形のピーク強度情報を用いてもよい。
次に、図28は、FMCW方式に代えることができる光切断方式について説明するための図である。
Claims (12)
- 光を対象物に照射し、前記対象物からの反射光を受光する距離計測ヘッドと、
前記反射光に基づいて距離検出波形を生成する距離計測装置と、
前記距離検出波形を解析して前記対象物までの計測距離値を算出する制御装置と、
を備え、
前記制御装置は、前記距離検出波形の特徴量を算出し、補正式に前記特徴量を入力して前記計測距離値の誤差を補正する処理、及び信頼度重み付け式に前記特徴量を入力して前記計測距離値の誤差の信頼度重み付けを行う処理の少なくとも一方を行う
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記距離計測装置は、FMCW方式、OCT方式、TOF方式、または光切断方式を用いて前記反射光に基づいて前記距離検出波形を生成する
の伝搬時間の測定による
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記制御装置は、前記距離検出波形の前記特徴量として、分散、歪度、尖度、または重心を算出する
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記制御装置は、波形フィッティングに基づいて前記距離検出波形の前記特徴量を算出する
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記制御装置は、前記距離検出波形のピーク強度と周囲の検出波形のピーク強度との相対値に基づいて前記距離検出波形の前記特徴量を算出する
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記補正式、及び前記信頼度重み付け式の少なくとも一方のパラメータは、ユーザが変更可能である
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記制御装置は、信頼度重み付けされた測定点群を出力する
ことを特徴とする形状計測システム。 - 請求項7に記載の形状計測システムであって、
前記制御装置は、前記信頼度重み付けされた点群に対して、重み付け量に応じてノイズ除去し、フィッティングにより形状を算出する
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記制御装置は、段差を有する前記対象物を計測する場合、複数のピーク点を有する前記距離検出波形の特徴量に基づき、前記段差の位置を算出する
ことを特徴とする形状計測システム。 - 請求項1に記載の形状計測システムであって、
前記制御装置は、前記対象物のCADデータ、及び前記光の照射方向に基づいて前記対象物の傾斜角度、曲率半径、及び粗さを取得し、前記傾斜角度、前記曲率半径、及び前記粗さに基づいて、前記距離検出波形の前記特徴量を算出する
ことを特徴とする形状計測システム。 - 請求項10に記載の形状計測システムであって、
前記対象物の前記粗さを表す情報が前記CADデータに付加されていない場合、ユーザが前記粗さを表す情報を入力可能である
ことを特徴とする形状計測システム。 - 形状計測システムによる形状計測方法であって、
光を対象物に照射し、前記対象物からの反射光を受光するステップと、
前記反射光に基づいて距離検出波形を生成するステップと、
前記距離検出波形を解析して前記対象物までの計測距離値を算出するステップと、
前記距離検出波形の特徴量を算出し、補正式に前記特徴量を入力して前記計測距離値の誤差を補正する処理、及び信頼度重み付け式に前記特徴量を入力して前記計測距離値の誤差の信頼度重み付けを行う処理の少なくとも一方を行うステップと、
を含むことを特徴とする形状計測方法。
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