Quick RGB-IR Calibration Verification for Mass Production
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Solution Overview
Problem
Traditional lens calibration methods for cameras are time-consuming and require skilled personnel, making them inefficient for mass production, as they involve repeated calibration loops and precise adjustments to determine a flawless warp table for each camera module.
Innovation Solution
A system with a calibration device that stores warp tables in a pool, allowing for quick calibration by selecting pre-configured warp tables based on similarity in lens characteristics, and generating new tables when necessary, to reduce calibration time and resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional lens calibration methods are used to ensure accurate warp tables, then manufacturing precision is improved, but productivity deteriorates due to time-consuming repeated calibration loops
Solution Approach 1:
The system pre-calibrates multiple capture devices using traditional methods and stores their warp tables in a pool before mass production. This preliminary action allows quick selection of suitable warp tables during production, eliminating time-consuming repeated calibration loops while maintaining accuracy requirements.
Solution Approach 2:
Instead of performing full calibration on each device, the system copies pre-calculated warp tables from the pool to newly captured devices. This copying approach maintains manufacturing precision by using proven accurate tables while dramatically improving productivity through reuse of calibration data.
2Measurement precision
If traditional calibration methods with precise camera positioning are used, then measurement precision is improved, but device complexity increases due to requirements for skilled personnel and rotation/movement mechanisms
Solution Approach 1:
The system captures images of capture devices at various positions and uses image processing algorithms to automatically determine calibration parameters. This self-service approach eliminates the need for skilled personnel to manually position and rotate cameras, reducing device complexity while maintaining measurement precision through automated image analysis.
Solution Approach 2:
The system replaces mechanical positioning and rotation mechanisms with computational methods. Instead of using skilled personnel to physically move and orient cameras, the system uses image processing and algorithms to extract calibration information from images captured at different positions, substituting mechanical complexity with computational simplicity.
3Reliability
If full calibration is performed on every capture device, then reliability is improved, but loss of time increases significantly in mass production scenarios
Solution Approach 1:
The system includes an evaluation module that assesses the quality of selected warp tables by analyzing captured images. This feedback mechanism ensures that only warp tables meeting quality thresholds are used, maintaining reliability while avoiding time-consuming full calibration by verifying results through automated evaluation.
Solution Approach 2:
The system creates a pool of warp tables from multiple pre-calibrated devices that can be universally applied to similar capture devices. This multi-functionality allows a single pre-calibrated table to serve multiple devices, maintaining calibration quality through proven tables while dramatically reducing the time loss associated with repeating full calibration on each device.
Data Source
AI summary
A system comprising a plurality of capture devices and a calibration device. The capture devices may each comprise a warp table. The calibration device may be configured to store a plurality of configured warp tables in a warp table pool, perform a full calibration for one of the capture devices to generate the configured warp tables, initiate a quick calibration for the capture devices and apply one of the configured warp tables to the capture devices as the warp table. The calibration device may apply one of the configured warp tables to the capture devices by selecting one of the configured warp tables from the warp table pool in response to the quick calibration. If the quick calibration fails, the calibration device may generate a new configured warp table for the warp table pool in response to the full calibration and select the new configured warp table.