光学三维测量技术与应用

光学三维测量技术是一种可视化的测量技术,能完成复杂形体的点、面、形的三维测量,能实现非接触测量,在制造业和航空航天领域得到广泛应用。航空三维激光扫描与摄影测量技术利用激光测距原理和航空摄影测量原理,与基于全球定位系统(GPS)和惯性测量装置(IMU)的机载定位定向系统(POS)联接,可以快速获取大面积地球表面三维数据。本文对光学三维测量技术和航空三维激光扫描技术做一简单介绍,给出三维激光扫描技术在航空航天领域的几个应用。     

复杂铸件的三维测量

针对复杂铸件尺寸大,结构复杂,槽、腔多,测量时需兼顾测量效率和槽腔可测性的特点,提出了一种大视场双目光栅测量子系统和小视场光栅测量子系统相结合的立体视觉测量方法。该方法使用前者测量复杂铸件的外部可测部分;使用后者测量复杂铸件的槽腔等被遮挡部分。建立了两个测量子系统的数据拼接模型,给出了数据拼接模型参数的定标方法。最后,通过实验验证了该方法的可行性。实验结果表明：该系统测量数据拼接的均方根误差（RMSE）为0.22 mm,满足复杂铸件测量的精度要求。相比传统测量方法,该方法兼顾了测量复杂铸件速度快和可以灵活测量槽腔等被遮挡部分的特点,对工程应用具有实际指导意义。     

Application of 3D FEM-slab method to shape rolling

In this paper, a complex model combining the simplicity of the slab method and accuracy of the finite element method was developed to save CPU time. When applied for the shape rolling, the deformation zone in the billet was divided into several proper slabs according to the shape of boundaries, in which each slab must match the force equilibrium along the longitudinal direction. Then, FEM was used to calculate sequentially the velocity field, metal flow, stress and strain distribution for each slab. By using only one slab in each iteration, the iteration range of traditional FEM was significantly reduced. Therefore, the memory capacity and computational time can be significantly reduced. Compared with traditional FEM, the results of this complex model were acceptable, verifying that the model proposed in this paper is an effective method.     

Shape measurement based on fiber-optic technique for complex internal surface

Reverse engineering based on fiber-optic technique is a very new topic in CAD/CAM fields. A novel single-mode fiber-optic sensor is presented based on the principle of beam reflection to implement the digitizing of complex surface shape. The fibers in the sensor probe are arranged like a spoke with eight symmetrically cross-arranged receiving fibers and one centered emitting fiber. Thus, the sensor can compensate for the offsets caused by fluctuations of surface reflectivity and light power and is fit for application under rough and formidable conditions with noncontact, fast shape measurement. A prototype was developed based on the simulation results to verify the feasibility. With the GRIN lens on the exit end of the single-mode emitting fiber, the lateral resolution was greatly improved compared with former multimode fiber-optic displacement sensors. Preliminary experiments indicated that the estimated uncertainty of displacement measurement was better than ±2 μm, and the uncertainty of ±5.6 μm can be obtained when measuring a MJ20×1.5 thread.     

基于从明暗恢复形状的雕塑曲面三维形状重构

在从明暗恢复形状问题(由物体二维灰度图象提取其表面高度值的问题)的基本原理和数学模型的基础上,提出了一种求解该问题的算法,利用变分原理和有限差分方法得到了算法的迭代方程。这里将该算法应用于雕塑曲面的三维形状重构,通过对人工合成图象的计算及数控加工实验证明了该算法具有一定的实用价值。     

A low cost 3D shape measurement method based on a strip shifting pattern

We present a simple, low cost but fast 3D shape measurement method. There is no limitation on the object's material and texture. We use a projector to project a strip shifting pattern on the object, and a digital camera to record videos of the scene. The distortion of the strip shadow on the object is used to get the object's 3D information. A novel space-time edge finding method is introduced to position the shadow edge accurately. This edge finding method overcomes the effect of inter-reflection and high light. Using this space-time information, we can calculate the pixels' 3D coordinates. To get the 3D shape of an object with black texture, we improve the black strip pattern to a 3-color strip pattern. The bad data are filtered by a post-processing 3D filter, which makes full use of the neighborhoods' geometric constraints and the view point constraint. Meanwhile, our measurement method is fast, regardless of the complexity of the shape.     

大型自由曲面移动式三维视觉测量系统

本文介绍了一种移动式三维视觉测量系统，用于大型物体自由曲面的测量。传感器采用双目立体视觉方式，并结合编码结构光技术，使匹配过程简化。传感器移动到大型物体周围对各局部区域进行测量。采用一个平面靶标作为中介，建立了传感器位姿变换矩阵的优化目标函数，根据靶标上多个特征点求解出该矩阵，即拼接矩阵。传感器在各个位置所测三维数据通过拼接矩阵统一到全局坐标系下。视觉测量系统在2个位置对维纳斯石膏像进行了测量，并进行拼接。结果表明，该测量系统操作简单，适用范围广；x、y、z坐标拼接RMS误差分别为0．038mm、0．022mm和0．135mm。     

基于单经纬仪的视觉测量三维数据拼接方法

本文针对大型自由曲面三维视觉测量中的数据拼接问题，建立了经纬仪透视投影模型，提出了以平面靶标为中介坐标系，以经纬仪坐标系为全局坐标系的三维数据拼接方法。在大型自由曲面的若干测量子区域附近放置一个平面靶标，通过视觉传感器拍摄平面靶标上的特征点，求得视觉传感器坐标系到靶标坐标系的变换矩阵；通过经纬仪观测靶标上的特征点，求得靶标坐标系到经纬仪坐标系的变换矩阵。因此，可求得视觉传感器坐标系到经纬仪坐标系的变换矩阵。将视觉传感器所测得的各子区域的三维数据统一到了经纬仪坐标系下，即完成了大型自由曲面的全局测量。经实验验证，数据拼接的RMS误差小于0．487mm。     

条纹投影三维形貌测量的变分模态分解相位提取

针对条纹投影三维形貌测量涉及的相位提取,提出了一种基于变分模态分解的单幅条纹投影相位提取方法。通过建立变分模态分解模型和极小化变分模态分解将单幅投影条纹图分解成背景部分、条纹部分和噪声部分。然后对得到条纹部分进行Hilbert变换和反正切变换得到包裹相位;对其进行质量导向相位解包裹和Zernike多项式去载频得到解包裹相位。将该方法与Fourier变换、连续小波变换进行了对比,结果显示:本文提出的相位提取方法相位误差为3.14×10-4,小于Fourier变换和连续小波变换方法对应的误差3.30×10-4和6.52×10-4。模拟和实验结果表明:本文提出的方法在处理具有边缘信息投影条纹图时具有优势,能够提取出更准确的相位信息,可有效地用于含边缘不连续和突起的三维物体测量。     

复杂曲面机器人三维测量的误配准筛除算法

航空叶片属于复杂异形曲面,作为航天发动机的重要零件之一,其形状结构的高精度检测必不可少。复杂异形曲面由于其边缘曲率复杂,使得目前的点云配准技术尚无法满足其高精度配准需求,针对航空发动机叶片复杂异形曲面高精度配准的要求,提出了基于多尺度描述子的空间角度差分阈值筛除误配准对的配准算法,创新性的通过多尺度特征与空间角度差分阈值筛除算法相结合的方法实现高精度的异形曲面配准。该方法可以有效降低误匹配点和噪声点对配准效果的影响。实验表明,本算法对于航空叶片复杂异形曲面具有很好的配准效果,配准精度高,且具有良好的鲁棒性。     

形貌视觉测量中立体拼接靶标的设计及应用

设计了一种正六棱柱形状的立体拼接靶标,以靶标侧面6个棋盘格的角点作为全局控制点。基于近景摄影测量技术,建立立体靶标的6个单元模型,通过计算模型内摄站间的相对位姿,推导出棋盘格角点在所属单元模型的局部坐标。以公共棋盘格为中介,确立相邻单元模型的坐标系转换关系。建立靶标的全局坐标系于1号棋盘格,推导该棋盘格平面与其像平面间的单应性矩阵,从而确立全局坐标系和1号棋盘格所处单元模型的坐标系的转换关系。依次递推实现全局坐标系和每个单元模型坐标系的转换,进而计算出全部靶标角点的全局坐标,再经光束平差算法获取精确值。以玻璃表面棋盘格的角点间距作为评价指标,拼接精度优于0.15 mm/m。基于立体拼接靶标的拼接试验表明,实体模型表面4个子区域的局部点云可被精确地拼接成整体点云。与基于全局控制点和平面靶标的拼接方法相比,本方法亦具有更高的拼接精度。     

基于彩色条纹投影术的三维形貌测量

物体表面三维形貌数据的获取在智能制造、航空航天、文物保护、医疗卫生、远程教育等领域有着广泛的应用。三维形貌数据的获取受限于系统硬件的性能,特别是现有数字投影系统的投影速度,无法快速测得物体面形的三维形貌。彩色成像和投影系统的出现,为并行多颜色通道三维成像系统提供了新的研究方向。详细综述了基于彩色条纹投影术的三维形貌数据测量研究的现状。具体包括彩色条纹投影术的基本原理、彩色条纹调制和解调相关技术、三维成像系统的标定、以及未来的研究方向。接着给出几个利用彩色条纹投影术获取物体表面三维形貌和彩色纹理的实例。为彩色条纹投影术测量物体表面三维形貌数据提供了详尽的综述,并指明了未来潜在的研究新方向。     

一种基于相位法的彩色三维形貌测量方法

基于相位法的三维形貌测量。提出了一种建立被测物体彩色三维形貌的方法。该方法采用主动光源投射一组光强呈余弦变化的光栅。并由一台黑白CCD工业摄像机对被测物体拍摄从而实现三维形貌的重建;然后对被测物体进行三色光投射。同时黑白工业摄像机拍摄被测物体,通过对所得图片进行分析。实现被测物体的色彩恢复。实验结果表明,该方法能够快速准确的获得被测物体的彩色三维形貌,色彩度误差小,可有效解决黑白工业相机无法进行色彩捕捉这一问题。     

三维光电振动测量技术的校准方法研究

为了分析三维光电振动测量仪测量的三维数据准确性,提出了一种利用标准小球做相对校准的简便方法。组成三维光电振动测量仪的5台激光测振仪发出的5束激光同时经过1个透镜,聚焦在位于透镜焦点处且安装在振动源上的标准小球球面上,软件处理小球振动时的三维分量,并与小球3个正交方向放置的3台激光测振仪测得的数据对比。通过微调小球的摆放位置,测量小球不同振动方向的三维振动信息,最后对数据进行误差分析,测量结果验证了该校准方法的可行性和适用性。     

基于形状特征的管路接头测量和三维重建方法

针对复杂管路系统中的接头同步测量和三维重建的难题,提出一种基于形状特征的管路接头测量和三维重建方法。该方法通过接头CAD模型边缘轮廓和实物图像边缘轮廓进行形状特征匹配来实现接头空间位姿的测量。首先通过建立虚拟相机"视点球"获取接头CAD模型边缘轮廓的投影图像,经过金字塔分层组成接头的形状特征图库;然后与获取的接头实物图像边缘轮廓进行对比匹配;最后利用最小二乘法迭代求解接头的空间位姿,并重建接头的三维模型。开发了管路多目视觉测量系统并进行了接头位姿测量和管路三维重建实验,实验表明该方法的接头测量和三维重建时间可控制在1min内,位置误差为0.654mm,姿态误差为0.73°,测量和重建的效率与精度满足工程要求。     

快速离焦投影三维测量技术

随着数字投影技术的发展,基于投影的三维面型测量技术在多种场合得到广泛应用。基于相移的结构光投影测量技术以其算法简便精度较高得到较快发展。但投影仪为非线性仪器,会影响强度变化,进而影响相位测量精度;此外由于投影仪工作原理的投影速度受到限制。离焦投影技术的出现为高速测量和高精度测量提供了新的方法。总结了目前国内外对离焦投影技术的研究现状;从投影工作原理、相移算法、解包裹算法、误差补偿、条纹调制、标定技术及离焦投影技术的相关技术细节进行全面介绍,为数字离焦投影三维测量工作的研究提供参考。     

基于全站仪三坐标测量系统的测量方法

由数台全站仪和一台计算机组成的全站仪测量系统进行前方交会测量,可以完成在工业测量中的单点坐标的测量、特别是大尺寸工件的测量。现根据全站仪测量系统的测量原理,对较大范围内检测点的空间三坐标计算方法和误差作一分析探讨。以实现如汽车车身、轮船船体、空中客车等加工制造中大工件的在线检测。     

曲率半径的高精度测量及其不确定度

为了高精度测量光学元件的曲率半径,提出了一种利用反射式计算全息元件结合波长移相干涉测长技术测量光学球面曲率半径的方法.测试中,将反射式计算全息元件作为基准来标定所用标准镜头参考面的曲率半径,利用波长移相干涉技术测量干涉腔腔长,通过计算分析得到被测元件的曲率半径.文中描述了该方法的系统构成及其工作原理.结合实例,运用理论分析与软件仿真模拟分析了方法的测量不确定度.最后,利用实验室现有的商用波长移相干涉仪进行了实验验证.对一口径为100 mm的球面样品进行曲率半径的测量,得到的结果为157.108 3 mm;利用接触式球径仪法对同一样品进行对比测量,结果显示相对误差小于0.02％.与其它目前已有的非接触式曲率半径测量方法相比,提出的方法具有误差源少、测量精度高、易于操作等优点.     

A practical sampling method for profile measurement of complex blades

Blade is one of the most important parts in turbine machinery. The complex geometry of blades not only makes them difficult to fabricate, but also leads them difficult to inspect. Typically, the surface of blades is measured by using coordinate measuring machine (CMM). Since the measurement time and cost increase proportionally as the increase of measurement points, it is essential to sample measurement points which can represent entire blade with sufficient confidence and accuracy. In order to achieve a certain allowable deviation with a suitable set of points, a practical sampling method for surface measurement of blades was studied. Firstly, the leading edge curve and trailing edge curve were supposed to represent the twisted and bend information of blades. A sampling method based on maximum chordal deviation for leading edge curve and trailing edge curve was researched. Further, a fusion approach for sampling points on both edge curves, which determine the cross-sections, was proposed. Secondly, the inspection points sampling method for sectional curves were investigated. Finally, two simulation and one experimental examples were used to demonstrate the sampling methodology. The results indicated that the approach of this study can ensure the measurement precision at high curvature potion by measuring a small number of points.     

Optical 3D profilometer for in-process measurement of microsurface based on phase retrieval technique

We have proposed an optical method that can be applied to in-process or in situ measurement of the microsurface profile. The present method is based on optically performed spectral analysis and the phase retrieval technique. Spectral information of a surface profile is obtained by measuring the Fraunhofer diffraction intensity. The phase retrieval technique is used to reconstruct the surface profile from the measured spectrum. We have developed an instrument on the basis of the general principles of the present method, and measured the surface of a reference standard having rectangular pockets 44 nm deep at intervals of 10 μm. The measured surface profile was in good agreement with the nominal dimensions of the specimen as well as the surface profile obtained by atomic force microscopy (AFM).