Integrated Reference Plate for Deflectometry Sensor Calibration
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Solution Overview
Problem
Conventional deflectometry sensor systems face challenges in calibration due to the complexity of determining the precise relative positions of cameras and image generation devices, especially when mounted on robots, which affects the accuracy of geometric measurements and defect detection on reflective surfaces.
Innovation Solution
A reference plate with a reflective surface and predefined markings is used to simplify the calibration process, allowing multiple system parameters to be checked and calibrated using a single tool, including coded marks and Siemens stars to account for perspective distortions and ensure precise positioning of cameras relative to the measurement object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional calibration methods using separate reference targets for camera and screen are used, then individual components can be calibrated, but the overall system calibration becomes laborious and complicated
Solution Approach 1:
The patent combines the camera calibration target and screen calibration target into a single integrated reference plate. The reference plate contains both a camera calibration pattern (first pattern) and a screen calibration pattern (second pattern) on the same physical object, allowing simultaneous calibration of both components in one setup procedure, thereby reducing the laborious and complicated multi-step conventional calibration process
Solution Approach 2:
The reference plate serves multiple functions: it acts as both a camera calibration target and a screen calibration target, and also provides reference markings for spatial positioning. This multi-functional design eliminates the need for separate reference objects for different calibration purposes, simplifying the overall calibration workflow while maintaining precision
2Reliability
If multiple reference objects are used for calibrating different components, then comprehensive calibration is possible, but the calibration time and effort increase significantly
Solution Approach 1:
The patent merges multiple calibration functions into a single reference plate that can be used for camera calibration, screen calibration, and spatial reference simultaneously. This consolidation allows the operator to perform comprehensive system calibration using one reference object instead of multiple separate reference targets, significantly reducing calibration time while maintaining reliability through the integrated design
3Adaptability or versatility
If the deflectometry sensor is moved by robot to multiple positions for comprehensive measurement, then large objects can be inspected, but the precise position and orientation of the sensor relative to the measurement object must be accurately determined
Solution Approach 1:
The reference plate serves as an intermediary object that establishes a common reference frame between the robot's coordinate system and the measurement object's coordinate system. By providing known reference markings that can be detected at different robot positions, the system can accurately determine the sensor's position and orientation relative to the measurement object, enabling comprehensive measurement of large objects while maintaining precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables a rapid, efficient, and accurate calibration of deflectometry sensor systems, ensuring precise geometric measurements and defect detection, while also allowing for online monitoring and compensation of system parameters, thereby maintaining consistent measurement results over time.
Implementation Method 1
a reference plate (5) for calibrating and/or checking a deflectometry sensor system (1), wherein the deflectometry sensor system (1) includes an image generation device (2) and a capturing device (3) having at least one capturing element (3), wherein a reflective surface (5) of the reference plate (5) is provided with a predefined pattern (6, 7) including markings (6, 7)
Data Source
AI summary
The disclosure relates to a reference plate for calibrating and/or checking a deflectometry sensor system, said deflectometry sensor system including an image generation device and a capturing device having at least one capturing element, wherein the reference plate includes a reflective surface, and wherein, for the purpose of checking at least one system parameter of said deflectometry sensor system, the reflective surface is provided with a predefined pattern including markings. A corresponding method for calibrating and/or checking a deflectometry sensor system is moreover indicated.