A High Precision Approach to Calibrate a Structured Light Vision Sensor in a Robot-Based Three-Dimensional Measurement System

A robot-based three-dimensional (3D) measurement system is presented. In the presented system, a structured light vision sensor is mounted on the arm of an industrial robot. Measurement accuracy is one of the most important aspects of any 3D measurement system. To improve the measuring accuracy of the structured light vision sensor, a novel sensor calibration approach is proposed to improve the calibration accuracy. The approach is based on a number of fixed concentric circles manufactured in a calibration target. The concentric circle is employed to determine the real projected centres of the circles. Then, a calibration point generation procedure is used with the help of the calibrated robot. When enough calibration points are ready, the radial alignment constraint (RAC) method is adopted to calibrate the camera model. A multilayer perceptron neural network (MLPNN) is then employed to identify the calibration residuals after the application of the RAC method. Therefore, the hybrid pinhole model and the MLPNN are used to represent the real camera model. Using a standard ball to validate the effectiveness of the presented technique, the experimental results demonstrate that the proposed novel calibration approach can achieve a highly accurate model of the structured light vision sensor.