Rapid Global Calibration Technology for Hybrid Visual Inspection System

Vision-based methods for product quality inspection are playing an increasingly important role in modern industries for their good performance and high efficiency. A hybrid visual inspection system, which consists of an industrial robot with a flexible sensor and several stationary sensors, has been widely applied in mass production, especially in automobile manufacturing. In this paper, a rapid global calibration method for the hybrid visual inspection system is proposed. Global calibration of a flexible sensor is performed first based on the robot kinematic. Then, with the aid of the calibrated flexible sensor, stationary sensors are calibrated globally one by one based on homography. Only a standard sphere and an auxiliary target with a 2D planar pattern are applied during the system global calibration, and the calibration process can be easily re-performed during the system’s periodical maintenance. An error compensation method is proposed for the hybrid inspection system, and the final accuracy of the hybrid system is evaluated with the deviation and correlation coefficient between the measured results of the hybrid system and Coordinate Measuring Machine (CMM). An accuracy verification experiment shows that deviation of over 95% of featured points are less than ±0.3 mm, and the correlation coefficients of over 85% of points are larger than 0.7.