Industrial Camera Calibration Support via Pattern Overlay Visualization
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Solution Overview
Problem
Industrial camera calibration processes are inefficient due to the difficulty in determining the optimal positions and angles for capturing calibration patterns, leading to suboptimal calibration accuracy and increased user labor in ensuring proper image acquisition.
Innovation Solution
A calibration operation support device that includes a processing unit which instructs a display device to overlay the positions and accuracy improving effects of captured calibration patterns on the image, allowing users to easily identify and arrange calibration patterns for improved image capture and reduced user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If users manually determine optimal positions for capturing calibration patterns, then calibration accuracy can be improved, but user labor and time consumption increase
Solution Approach 1:
The system automatically determines optimal capture positions by analyzing the calibration pattern distribution map generated from previously captured images. The processing device calculates position information based on the distribution of calibration patterns and instructs the camera to capture at the determined optimal position, eliminating the need for manual user intervention while maintaining high calibration accuracy.
Solution Approach 2:
The system provides feedback by displaying a distribution map that shows where calibration patterns have been captured and their effectiveness. This visual feedback allows the system to automatically adjust subsequent capture positions based on the analyzed distribution, creating a closed-loop optimization process that improves calibration accuracy without requiring repeated manual trial and error.
2Measurement precision
If multiple captured images are used for calibration, then calibration accuracy improves, but it becomes difficult to determine optimal positions and angles for capture
Solution Approach 1:
The system introduces an intermediary representation in the form of a distribution map that visualizes the effectiveness of previously captured calibration patterns. This distribution map serves as a mediator between the raw captured images and the determination of optimal capture positions, making it easier to analyze and interpret the effectiveness of different capture positions without manually reviewing multiple images.
Solution Approach 2:
The system transforms the complex multi-dimensional problem of determining optimal capture positions and angles into a simplified two-dimensional distribution map that shows the effectiveness of calibration patterns across the capture area. This dimensional simplification makes it much easier to identify optimal positions by visual inspection rather than analyzing multiple images in detail.
Data Source
AI summary
A calibration operation support device is applied to a system including an industrial camera and a display device displaying a predetermined image that is an image of a predetermined area being captured by the industrial camera, and includes a processing device configured to perform a calibration of the industrial camera based on captured images that are obtained by capturing a calibration pattern by the industrial camera. The processing device is further configured to instruct the display device to display positions of the calibration patterns in the captured images acquired as images to be used for the calibration in a manner superimposed on the predetermined image.