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Shao J F, Ni Y B, Meng Z Z, et al. Three-dimensional shape measurement of composite surface based on defocused binary display and fringe projection[J]. Opto-Electron Eng, 2024, 51(4): 240024. doi: 10.12086/oee.2024.240024
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Three-dimensional shape measurement of composite surface based on defocused binary display and fringe projection
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Abstract
Due to the different reflective properties of the diffuse and specular components in composite surface objects and the limitations imposed by the camera depth of field, defocusing of sinusoidal fringes occurs in specular imaging, leading to phase errors. To achieve the efficient and high-precision measurement of composite surface objects, this paper proposes a method for three-dimensional surface topography measurement by combining defocused binary patterns with sinusoidal fringes. Firstly, the paper partitions and calibrates the defocus level of the system based on the edge and second-order blur methods, addressing the issue of varying defocus levels of the reference surface due to the tilted placement of the camera. Then, a binary fringe phase error model is established to determine the optimal fringe width and the defocus range. Finally, defocus compensation is applied to the binary fringes in the slightly defocused region, ensuring that the captured fringes are within the optimal defocus range. Three-dimensional surface topography measurement is conducted based on this approach. Experimental results show that the proposed method reduces the error in the specular component from 0.033 mm to 0.019 mm, thereby improving the accuracy of composite surface measurement. -
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References
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Overview
In the field of smart manufacturing, there is a growing need for the precise measurement of composite surface components exhibiting both specular and diffuse reflection characteristics. The construction of a measurement system based on fringe projection and phase-shifting deflectometry allows for the non-destructive and rapid acquisition of three-dimensional information for composite surface objects. However, the structured light by reflecting from the measured surface, exhibits different imaging positions, significantly increasing the difficulty in camera focusing and leading to defocusing blur issues, causing phase errors.
To expand the system measurement range and achieve the efficient and high-precision measurement of composite surface objects, this paper proposes a method for three-dimensional surface topography measurement by combining defocused binary patterns with sinusoidal fringes. Firstly, considering the varying defocus levels on the same plane due to the angle between the camera and the reference plane, the paper introduces a method combining the edge and second-order blur methods. It utilizes a chessboard pattern to accurately partition and quantify the defocus level, completing system defocus calibration. Secondly, based on the established model of optimal defocus, period, and phase error for binary fringes, and considering the actual blur level within the system measurement range, the paper selects the optimal width of binary fringes and the range of defocus, determining smooth regions with minimal phase error. Then, considering that the tilted placement of the camera may cause some regions of the fringes to deviate from sinusoidal behavior, slightly defocused fringes outside the smooth regions are pre-compensated with a Gaussian filter. This is done by calculating the parameters of the Gaussian function and convolving it with the fringes, ensuring that the deformed fringe patterns captured by the camera are within the optimal defocus range. This operation effectively suppresses high-order harmonics of binary fringes, expanding their applicability. Finally, appropriate binary fringes are displayed on two screens, and sinusoidal projection is displayed on the project, allowing the camera to capture clear sinusoidal and quasi-sinusoidal fringes. This method completes three-dimensional surface topography measurement for the composite surface.
The method employs the combination of the edge method and the second-order blur method for defocus assessment, achieving a measurement accuracy of 0.1 pixel or more and ensuring accurate measurement of full-field defocus in the dual-screen system. Experimental results show that the combination of binary and sinusoidal fringes proposed in this paper reduces errors in the specular part and the transition region between specular and diffuse components from 0.033 mm to 0.019 mm, enhancing the accuracy of composite surface measurement.
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Shao J F, Ni Y B, Meng Z Z, et al. Three-dimensional shape measurement of composite surface based on defocused binary display and fringe projection[J]. Opto-Electron Eng, 2024, 51(4): 240024. doi: 10.12086/oee.2024.240024
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Figure 1.
Schematic diagram of camera depth of field in composite surface measurement system
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Figure 2.
Principle of knife-edge method
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Figure 3.
Diagram of secondary defocusing method
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Figure 4.
Flow chart of system parameter selection strategy
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Figure 5.
Composite surface measurement system model based on fringe projection and direct phase measure deflectometry
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Figure 6.
Hardware setup of the composite surface measurement system
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Figure 7.
Defocus quantification method simulation. (a) Analysis of results of simulated edge method; (b) Estimation of defocus amount
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Figure 8.
Defocus calibration. (a) Edge defocus value; (b) Defocus values fitted to multiple positions using plane fitting
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Figure 9.
Analysis of phase error model. (a) Simulation of the phase error; (b) Experimental and simulation error comparison
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Figure 10.
Optimal defocus analysis of the LCD-reference surface. (a) Optimal defocusing selection; (b) Defocusing range of LCD
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Figure 11.
Reference plane spectrum analysis. (a) Binary at the front end; (b) Binary at the back end; (c) Modulated binary at the front end
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Figure 12.
Composite surfaces object. (a) Computer identification; (b) Ring step
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Figure 13.
Optimal defocus analysis of the LCD-measured step. (a) Optimal defocusing selection; (b) Defocusing amount for LCD component
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Figure 14.
Phase unwrapping and comparison of step. (a) Uncompensated binary fringes; (b) Sinusoidal fringes; (c) Compensated binary fringes; (d) Sinusoidal fringes; (e) Absolute phase of (a) ; (f) Absolute phase of (b) ; (g) Absolute phase of (c) ; (h) Absolute phase of (d)
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Figure 15.
Comparison of three-dimensional topography for specular components. (a) Uncompensated binary fringes; (b) Sinusoidal fringes; (c) Compensated binary fringes
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Figure 16.
Results of three-dimensional surface topography reconstruction for composite objects. (a) Surface topography of computer identification; (b) Reconstructed depth of step
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