利用高帧频相机检测运动控制轴精细形变

Fine Deformation Detection of Motion Control Axis with High Frame Frequency Camera

在运动控制应用场景中,由于疲劳等原因会导致设备微小形变,因此需要更加密集的观测手段与恢复方法。考虑到待检设备的摄影测量属性及高帧频相机高信息量特性,利用240帧/s的高帧频电荷耦合元件(charge coupled device,CCD)相机结合摄影测量方法实现对运动控制轴形变信息的精确量测,具体步骤如下:(1)固定标定板,由运动控制器控制高帧频相机运动,并对标定板进行连续拍摄。(2)提取标定板角点坐标,提出基于角点几何与运动特征的角点坐标精确定位方法。(3)计算相机坐标序列,恢复相机运动的高密度点轨迹。实验结果表明,由轨迹可精确地反映室内运动控制轴形变位置和形变量,实现亚毫米级形变检测,实际检测的运动轴最小倾斜角为0.012°,水平轴左端48.016 cm处存在0.98 mm的形变,竖直轴上端3.810 cm处形变量为2.00 mm。

Objectives:In the scene of motion control application,small deformation of equipment will be caused for the fatigue and other reasons,therefore the more intensive observation and the recovery methods are needed.Taking into account the photogrammetric properties of the equipment and the high-information of the high frame-frequency camera,the deformation detection of the motion control axis is realized by combining the high frame-frequency camera with the photogrammetric method.Methods:The indoor deformation detection environment is established using high frequency charge coupled device camera with 240 frame/s,motion controller and motion control axis that need to be detected.(1)Fixed the checkerboard calibration board,the motion of the high frame frequency camera are controlled by the motion controller,and continuously shoots the calibration board.(2)The corner coordinates of calibration plate are extracted,and the accurate positioning of corner coordinates based on the geometry and motion characteristics of corner are proposed.Corner geometry characteristic:The corner points of a checkerboard in the same direction locate in the same line.Motion characteristic:The coordinate variation between the corresponding corner points of two pictures of the calibration plate taken at different times is equal.(3)Calculating the camera coordinate sequence and restoring the high-density point trajectory of the camera motion.n pictures of the calibration plate are taken using the camera from different angles to calculate the elements of interior orientation of camera.The exterior orientation elements of camera for a new picture about the calibration plate,and the camera center coordinates can be solved by the homography between the pixel coordinates and the world coordinates,the camera high-density point of motion trajectory can be recovered.Results:(1)The maximum projection error of corner detection is less than 0.5 pixel,and the extracted corner is stable.(2)The camera reprojection error is less than 0.4 pixel,when the resolution of the object is in the range of1.13—2.04 mm,and it meets the requirements of deformation detection accuracy.For the camera moving along the straight line to collect the calibration plate image,400 frames of the calibration plate image are randomly selected from the acquisition calibration plate image for reprojection,the maximum re-projection error is about 0.3 pixel,which can meet the requirements of deformation detection accuracy.(3)Comparing the deformation detection method with a 3 D laser scanner with higher accuracy and normal industrial camera,the recovered motion trajectory of the high frequency camera is consistent with the scanning trajectory of the 3 D laser scanner.The actual detection of this method shows that the deformation is 0.98 mm at the left end of the horizontal axis 48.016 cm and at the upper end of the vertical axis 3.810 cm is 2.00 mm.The inclination of the horizontal axis is 0.012°in the Y direction and in the Z direction is 0.370°.The inclination of vertical axis is 0.021°in the X direction and 0.509°in the Z direction.The deformation of the control axis is not detected by the normal industrial camera.The inclination of the horizontal axis in the Y direction is0.015°and is 0.375°in the Z direction,the inclination of vertical axis is 0.022°in the X direction and 0.527°in the Z direction.Conclusions:The experimental results show that data is collected by the high frame frequency camera can reflect the details of the deformation of control axis,the actual deformation position and deformation quantity can be accurately obtained,and realize the sub-millimeter deformation detection.It effectively makes up for the low frame rate of normal industrial camera in deformation detection,and has certain practical value in industrial deformation detection.