Research progress of grating projection on machine 3D topography inspection technology
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摘要:
基于视觉的测量方式对航天、军工以及电子芯片等先进制造领域具有良好应用前景以及深远的发展意义，而基于结构光的在机三维视觉检测技术，是目前精密加工领域的热点与难点之一。本文以结构光在机三维测量流程为主线，将其中的关键技术，包括测量标定、相位优化求解、在机三维点云处理及不同特征曲面重构中的技术要求、涉及的方法和原理、相关研究现状及目前存在的问题，进行论述与总结。最后，根据未来相关技术的实际需求，在加工现场标定、动态实时三维重构、亚微米及纳米级测量、测量-加工一体化数据传输技术等方面进行了展望，并提出了相应的研究思路。
Abstract:Vision-based measurement has good application prospects and far-reaching development significance for advanced manufacturing fields such as aerospace, the military industry and electronic chips. Among them, on-machine 3D vision detection technology based on structured light is one of the hotspots and challenges in the field of precision machining. Based on the on-machine 3D measurement process of structured light, we discuss and summarize the key technologies, including its technical requirements, methods and principles involved, related research status and existing problems in the measurement calibration, phase optimization solution, on-machine 3D point cloud processing and reconstruction of different feature surfaces. Finally, according to the actual needs of relevant technologies in the future, prospects are made with regard to processing field calibration, dynamic real-time 3D reconstruction, sub-micron and nano measurement, and measurement processing integrated data transmission technology, with the corresponding research ideas put forward.
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图 2 基于结构光的在机检测系统架构
Figure 2. Architecture of an on-machine detection system based on structured light
图 4 本课题组研发的单目结构光智能在机检测平台
Figure 4. Monocular structured light intelligent on-machine detection platform developed by our research group
图 13 基于GA-BP算法的点云孔洞修补流程
Figure 13. Point cloud hole repair process based on the GA-BP algorithm
表 1 光学测量系统平台性能及特点
Table 1. Performance and characteristics of the optical measurement system platform
测量系统平台 测量精度 距离量程 优点 缺点 适用场景 电子经纬仪 10 μm 0~150 m 具有误差自修正功能，
抗干扰性强内部元器件制造
误差制约测量精度大尺寸零件装配
及尺寸检测结构光投影测量系统 0.1~20 μm 0.1~10 m 非逐点检测，测量效率高 测量过程受反光影响 复杂形貌零件，高效测量 激光扫描仪 0.1~10 μm 0~80 m 测量精度高，便携性好 测量效率较低 小尺寸零件，动态测量 机械臂测量系统 50 μm 0~5 m 自动化程度高 场景约束性强，便携性较差 全自动化加工检测场景 白光干涉仪 纳米级或亚纳米级 150 μm~20 mm 测量精度较高 使用条件及要求较苛刻，
测量效率低超精密加工及3C电子检测 
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表 3 典型的光饱和优化方法对比
Table 3. Comparison of typical optical saturation optimization methods
代表性学者 技术方法 优点 缺点 适用场景 Pinzek [29] 多重曝光控制法 曝光参数控制较方便，无需额外硬件系统 难以根据环境定量精确控制曝光，
耗时长环境光照影响较为主要时的检测 Liu [32] 全自动快速最佳曝光计算方法 检测过程自动化水平
较高易影响反射率较小部位，造成曝光
不足表面尺寸较大的反光物体检测 陈龙[35] 局部自适应条纹投影法 具有针对性的处理，
不影响其他区域像素准确的灰度阈值较难
确定叶片、轴类表面反射率
差异大的对象检测Liu [37] 多目视点配准法 测量精度
较高受测量空间限制，欠缺灵活性 小范围精密物体的在机检测 Zhang [38] 偏振滤光
片法可较精确控制光平衡 需要添加额外的光学及控制硬件 镜面物体的在机检测
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表 4 在机动态相位补偿代表性方法对比
Table 4. Comparison of representative methods of on machine dynamic phase compensation
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表 5 常用的离群点去除方式
Table 5. Common outlier removal methods
离群点去除方法 适用场景 基于迭代优化算法 适合于在杂乱噪声中搜寻临近目标点 基于邻域信息的
点云聚类算法适合对具有特定类型的
点云数据进行分类基于点云频率的滤波方式 适合对较复杂形状点云模型的分割计算
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表 6 不同类型曲面形貌重构技术对比
Table 6. Comparison of different types of surface reconstruction technologies
曲面类型 典型代表 曲面特点 测量难点 适用测量策略 曲面拟合方法 大尺寸曲面零件 涡轮发动机叶片、航空曲面零件 形状较规律，曲面尺寸数米至数十米 一次扫描难以测量出完整表面点云，且数据计算量庞大 采用柔性测量装置并配合多视角点云拼接方式 曲面片直接
拟合法微型曲面零件 微型精密半导体零件、精密光学器件 曲面尺寸较微小
(毫米级)点云分割难度较大，且较难解决
过拟合和欠拟合问题搭载光学高倍镜头和立体显微镜的光栅条纹投影法的测量方式 样条曲线
拟合方法复杂形状及曲面结合体 复杂腔体类零件 结构复杂，面数较多 点云模型拟合困难，测量繁琐，难以获得高精度且完整的点云模型 接触式与非接触式结构
光结合的测量方式基于特征约束及交互式曲面拟合方法
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