Out-of-Focus Projector Calibration Method with Distortion Correction on the Projection Plane in the Structured Light Three-Dimensional Measurement System

The three-dimensional measurement system with a binary defocusing technique is widely applied in diverse fields. The measurement accuracy is mainly determined by out-of-focus projector calibration accuracy. In this paper, a high-precision out-of-focus projector calibration method that is based on distortion correction on the projection plane and nonlinear optimization algorithm is proposed. To this end, the paper experimentally presents the principle that the projector has noticeable distortions outside its focus plane. In terms of this principle, the proposed method uses a high-order radial and tangential lens distortion representation on the projection plane to correct the calibration residuals caused by projection distortion. The final accuracy parameters of out-of-focus projector were obtained using a nonlinear optimization algorithm with good initial values, which were provided by coarsely calibrating the parameters of the out-of-focus projector on the focal and projection planes. Finally, the experimental results demonstrated that the proposed method can accuracy calibrate an out-of-focus projector, regardless of the amount of defocusing.