Diagnosing multipath interference and eliminating multipath interference in 3D scanners using projection patterns

• US 9,453,717 B2
• Filed: 12/23/2013
• Issued: 09/27/2016
• Est. Priority Date: 04/15/2011
• Status: Active Grant

• Current Assignee: Faro Technologies Incorporated
• Original Assignee: Faro Technologies Incorporated
• Inventors: Bridges, Robert E.
• Primary Examiner(s): Philippe, Gims
• Assistant Examiner(s): Shahnami, Amir
• Application Number:
  US14/139,021
• Publication Number:
  US 20140267619A1
• Time in Patent Office: 1,009 Days
• Field of Search: 348/46
• US Class Current: 1/1
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates
• CPC Class Codes: G01B 11/2513 with several lines being projected in more than one direction, e.g. grids, patterns
• CPC Class Codes: G01B 11/2531 using several gratings, projected with variable angle of incidence on the object, and one detection device
• CPC Class Codes: G01B 21/045 Correction of measurements G01B9/02055 takes precedence
• CPC Class Codes: G01B 5/004 for measuring coordinates of points
• CPC Class Codes: G01C 3/10 using a parallactic triangle with variable angles and a base of fixed length in the observation station, e.g. in the instrument
• CPC Class Codes: G01S 17/003 Bistatic lidar systems; Multistatic lidar systems
• CPC Class Codes: G01S 17/48 Active triangulation systems, i.e. using the transmission and reflection of electromagnetic waves other than radio waves
• CPC Class Codes: G01S 17/66 Tracking systems using electromagnetic waves other than radio waves
• CPC Class Codes: G06T 2200/04 involving 3D image data
• CPC Class Codes: G06T 2207/10028 Range image; Depth image; 3D point clouds
• CPC Class Codes: G06T 7/593 from stereo images
• CPC Class Codes: G06T 7/70 Determining position or orientation of objects or cameras camera calibration G06T7/80
• CPC Class Codes: H04N 13/204 using stereoscopic image cameras stereoscopic photography G03B35/00
• CPC Class Codes: H04N 13/239 using two 2D image sensors having a relative position equal to or related to the interocular distance H04N13/243 takes precedence
• CPC Class Codes: H04N 13/254 in combination with electromagnetic radiation sources for illuminating objects
• CPC Class Codes: H04N 13/275 from 3D object models, e.g. computer-generated stereoscopic image signals

Abstract

A method for determining 3D coordinates of points on a surface of the object by providing a non-contact 3D measuring device having a projector and camera coupled to a processor, projecting a pattern onto the surface to determine a first set of 3D coordinates of points on the surface, determining susceptibility of the object to multipath interference by projecting and reflecting rays from the measured 3D coordinates of the points, selecting a pattern as a single line stripe or a single spot based on the susceptibility to multipath interference, and projecting the pattern onto the surface to determine a second set of 3D coordinates.

Claims

1. A method of object measurement to determine three-dimensional (3D) coordinates of points on a surface of an object, the method comprising:

providing an assembly that includes a projector and a camera, wherein the projector and the camera are fixed in relation to one another, there being a baseline between the projector and the camera, the baseline being a line segment that has a distance equal to a baseline distance, the projector having a light source configured to emit projected light along a general direction of propagation given by a first axis, the assembly having a central plane that includes the first axis and the baseline, the projected light having any of a plurality of patterns in a first plane, the first plane being perpendicular to the first axis, the camera having a lens and a photosensitive array, the camera having a camera field of view, the lens configured to image a reflected portion of the projected light that is within the camera field of view onto the photosensitive array and to produce an electrical signal in response;

providing a processor electrically coupled to the projector and the camera;

selecting by the processor a first pattern from among the plurality of patterns;

emitting from the projector onto the surface, in a first instance, a first projected light having the first pattern;

reflecting into the camera a portion of the first projected light as a first reflected light;

forming with the lens a first image of the first reflected light on the photosensitive array and producing a first electrical signal in response;

determining with the processor a first set of 3D coordinates of first points on the surface, the first set based at least in part on the first pattern, the first electrical signal and the baseline distance;

determining with the processor a simulation in which the processor projects first rays from the projector to the first points and calculates for each first ray an angle of reflection of a secondary ray from each of the first points and determining that the angle of reflection of at least one of the secondary rays intersects the object to form a second image on the photosensitive array that interferes with the first reflected light;

selecting by the processor a second pattern from among the plurality of patterns, the second pattern being in the first plane, the second pattern being a single line stripe or a single spot, the second pattern based at least in part on the determining that the angle of reflection of at least one of the secondary rays intersects the object to form a second image on the photosensitive array that interferes with the first reflected light;

emitting from the projector onto the surface, in a second instance, a second projected light having the second pattern;

reflecting into the camera a portion of the second projected light as a second reflected light;

forming with the lens a second image of the second reflected light on the photosensitive array and producing a second electrical signal in response;

determining with the processor a second set of 3D coordinates of at least one second point on the surface, the second set based at least in part on the second pattern, the second electrical signal, and the baseline distance; and

storing the second set of 3D coordinates.

2. The method of claim 1 wherein the determining that the secondary ray intersects the object includes determining the secondary ray intersects a first portion of the surface, the first portion of the surface being that portion of the surface that is within the camera field of view.

3. The method of claim 1 further including steps of:

combining the first set of 3D coordinates and the second set of 3D coordinates into a third set of 3D coordinates;

eliminating a portion of the third set of 3D coordinates to obtain a fourth set of 3D coordinates based at least in part on the determining that the angle of reflection of at least one of the secondary rays intersects the object to form a second image on the photosensitive array that interferes with the first reflected light; and

storing the fourth set of 3D coordinates.

4. The method of claim 1 wherein, in the step of selecting by the processor the second pattern, the second pattern is a first single line stripe, the first single line stripe having a first stripe direction in the first plane.

5. The method of claim 4 further wherein the step of selecting by the processor the second pattern further includes steps of:

fixing the selected second pattern in an object frame of reference, the object frame of reference being fixed with respect to the object; and

rotating the assembly about the first axis until the central plane is perpendicular to the selected second pattern.

6. The method of claim 4 further including a step of sequentially moving the first single line stripe in the first plane, the first single line stripe retaining the first stripe direction for all sequential movements.

7. The method of claim 5 further including a step of sequentially moving the first single line stripe in the first plane, the first single line stripe retaining the first stripe direction for all sequential movements.

8. The method of claim 1 wherein, in the step of selecting by the processor the second pattern, the second pattern is a first single spot.

9. The method of claim 8 further including a step of sequentially moving the single spot on the first plane.

10. The method of claim 1 wherein:

the step of determining with the processor a simulation in which the processor projects first rays further includes steps of emitting from the projector onto the surface a first collection of epipolar lines, reflecting into the camera a portion of the first collection of epipolar lines;

reflecting into the camera a portion of the first collection of epipolar lines as a first diagnostic reflected light;

forming with the lens a first diagnostic image of the first diagnostic reflected light on the photosensitive array and producing a first diagnostic electrical signal in response;

determining with the processor whether the first diagnostic image includes a collection of straight lines; and

determining with the processor that the first diagnostic image includes lines that are not straight lines; and

in the step of selecting by the processor the second pattern, the second pattern is further based on the determining that the first diagnostic image includes lines that are not straight lines.

11. A method of object measurement to determine three-dimensional (3D) coordinates of points on a surface of an object, the method comprising:

providing an assembly that includes a projector and a camera, wherein the projector and the camera are fixed in relation to one another, there being a baseline between the projector and the camera, the baseline being a line segment that has a distance equal to a baseline distance, the projector having a light source configured to emit projected light along a general direction of propagation given by a first axis, the assembly having a central plane that includes the first axis and the baseline, the projected light having any of a plurality of patterns in a first plane, the first plane being perpendicular to the first axis, the camera having a lens and a photosensitive array, the camera having a camera field of view, the lens configured to image a reflected portion of the projected light that is within the camera field of view onto the photosensitive array and to produce an electrical signal in response;

providing a processor electrically coupled to the projector and the camera;

providing a CAD model of the object, the CAD model configured to provide computer-readable information for determining a 3D representation of the surface of the object;

providing computer readable media having computer readable instructions which when executed by the processor calculates 3D coordinates of points on the surface based at least in part on the CAD model;

determining with the processor a first set of 3D coordinates of first points on the surface, the first set based at least in part on the computer-readable information in the CAD model;

determining with the processor a simulation in which the processor projects first rays from the projector to the first points and calculates for each first ray an angle of reflection of a secondary ray from each of the first points and determining that the angle of reflection of at least one of the secondary rays intersects the object to form a second image on the photosensitive array that interferes with the first reflected light;

selecting by the processor a first pattern from among the plurality of patterns, the first pattern being in the first plane, the first pattern being a single line stripe or a single spot, the first pattern based at least in part on the determining that the angle of reflection of at least one of the secondary rays intersects the object to form a second image on the photosensitive array that interferes with the first reflected light;

emitting from the projector onto the surface a first projected light having the first pattern;

reflecting into the camera a portion of the first projected light as a first reflected light;

forming with the lens a first image of the first reflected light on the photosensitive array and producing a first electrical signal in response;

determining with the processor a second set of 3D coordinates of at least one second point on the surface, the second set based at least in part on the first pattern, the first electrical signal, and the baseline distance;

storing the second set of 3D coordinates.