3D Camera Calibration via Interpolated Plane Data
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Solution Overview
Problem
Current machine vision systems face challenges in accurately calibrating cameras across multiple discrete planes within a 3D volume space, particularly in scenarios where height variations occur, as existing methods require extensive calibration plate manipulation and setup, and are time-consuming, especially when space constraints limit access.
Innovation Solution
A system and method that uses linear interpolation/extrapolation to generate accurate camera calibration data for multiple discrete planes by calibrating at least two planes and applying this data to a third plane, eliminating the need for explicit approximation and reducing calibration plate setup complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used for multiple discrete planes, then calibration accuracy can be maintained, but the calibration process becomes time-consuming and requires extensive calibration plate manipulation
Solution Approach 1:
The system performs preliminary calibration at only two discrete planes (first and second planes) and uses linear interpolation to pre-calculate calibration parameters for intermediate planes. This preliminary action at minimal planes eliminates the need for time-consuming manual calibration at each individual plane, reducing overall calibration time while maintaining accuracy through mathematical interpolation of the calibrated parameters.
2Measurement precision
If calibration is performed at each discrete plane, then accurate calibration data is obtained, but the process requires extensive user involvement and complex setup
Solution Approach 1:
The system enables self-service calibration by automatically generating calibration parameters for all discrete planes through linear interpolation between two calibrated planes. The processor autonomously calculates the calibration parameters without requiring user intervention at each plane, and the system self-adjusts the calibration data based on the interpolated values, significantly reducing user involvement and setup complexity while maintaining calibration accuracy.
3Measurement precision
If calibration plate is manually positioned at each plane, then calibration can be performed, but space constraints limit access to certain heights
Solution Approach 1:
The system introduces linear interpolation as an intermediary mathematical method that bridges the gap between physically accessible calibration planes. By using the calibration data from two accessible planes as intermediaries, the system can generate accurate calibration parameters for planes that are physically inaccessible due to space constraints, effectively extending calibration coverage without requiring physical access to all planes.
4Productivity
If explicit approximation methods are used for calibration, then calibration can be performed, but accuracy is compromised
Solution Approach 1:
The system changes the calibration approach from using explicit approximation methods to using linear interpolation of calibration parameters between two precisely calibrated planes. This parameter change transforms the calibration process into one that maintains mathematical precision through linear relationships rather than approximations, thereby achieving both high calibration efficiency and accurate calibration results simultaneously.
Data Source
AI summary
This invention provides a system and method for generating camera calibrations for a vision system camera along three discrete planes in a 3D volume space that uses at least two (e.g. parallel) object planes at different known heights. For any third (e.g. parallel) plane of a specified height, the system and method then automatically generates calibration data for the camera by interpolating/extrapolating from the first two calibrations. This alleviates the need to set the calibration object at more than two heights, speeding the calibration process and simplifying the user's calibration setup, and also allowing interpolation/extrapolation to heights that are space-constrained, and not readily accessible by a calibration object. The calibration plate can be calibrated at each height using a full 2D hand-eye calibration, or using a hand-eye calibration at the first height and then at a second height with translation to a known position along the height (e.g. Z) direction.