3D Scanner Structured Light

Principle
Projecting a narrow
band of light onto a
three dimensionally
shaped surface
produces a line of
illumination that
appears distorted from
other perspectives
than that of the
projector, and can be
used for an exact
geometric
reconstruction of the
surface shape (light
section).
A faster and more
versatile method is the
projection of patterns
consisting of many
stripes at once, or of
arbitrary fringes, as this allows for the acquisition of a multitude of samples simultaneously. Seen
from different viewpoints, the pattern appears geometrically distorted due to the surface shape of
the object.
Although many other variants of structured light projection are possible, patterns of parallel stripes
are widely used. The picture shows the geometrical deformation of a single stripe projected onto a
simple 3D surface. The displacement of the stripes allows for an exact retrieval of the 3D
coordinates of any details on the object's surface.
Generation of stripe patterns

Two planar beams interfering
Two major methods of stripe pattern
generation have been established: Laser
interference and projection.
The laser interference method works with
two wide planar laser beam fronts. Their
interference results in regular, equidistant
line patterns. Different pattern sizes can be
obtained by changing the angle between
these beams. The method allows for the exact
and easy generation of very fine patterns with
unlimited depth of field. Disadvantages are
high cost of implementation, difficulties
providing the ideal beam geometry, and laser typical effects like speckle noise and the possible self
interference with beam parts reflected from objects. Also typically there is no means of modulating
individual stripes, e.g. with Gray codes (see below).
Fringe pattern recording system with 2 cameras (avoiding obstructions)


The projection method uses non coherent light and basically works like a video projector. Patterns
are generated by a display within the projector, typically an LCD (liquid crystal) or LCOS (liquid
crystal on silicon) display.
A proprietary projection method uses DLP (moving micro mirror) displays. DLP displays do not
absorb light significantly and are therefore allowing for highest light intensities. They also have an
extremely linear gray value reproduction, as they are steered by pulse length modulation.
Principally, stripes generated by display projectors have small discontinuities as to the pixel
boundaries in the displays. Sufficiently small boundaries however can practically be neglected as
they are evened out by the slightest defocus.
A typical measuring assembly consists of one stripe projector and at least one camera. For many
applications, two cameras on opposite sides of the projector have been established as useful.
Calibration
Geometric distortions by optics and
perspective must be compensated by a
calibration of the measuring
equipment, using special calibration
patterns and surfaces. A mathematical
model is used to describe the imaging
properties of projector and cameras.
Essentially based on the simple
geometric properties of a pinhole
camera, the model also has to take
into account the geometric distortions
and optical aberration of projector and
camera lenses. The parameters of the
camera as well as its orientation in
space can be determined by a series of calibration measurements, using photogrammetric bundle
adjustment.
Analysis of stripe patterns

There are several depth cues
contained in stripe patterns observed.
The displacement of any single stripe
can directly be converted into 3D
coordinates. For this purpose, the
individual stripe has to be identified,
which can e.g. be accomplished by
tracing or counting stripes (pattern
recognition method). Another
common method projects alternating
stripe patterns resulting in binary Gray
code sequences identifying the
number of each individual stripe
hitting the object. An important depth
cue also results from the varying
stripe widths along the object surface.
Stripe width is a function of the
steepness of a surface part, hence the
first derivative of the elevation. Stripe
frequency and phase deliver similar
cues and can be analyzed by Fourier
transform. Finally, wavelet transform
has recently been discussed for the
same purpose.
In many practical implementations, series of measurements combining pattern recognition, Gray
codes and Fourier transform are obtained for a complete and unambiguous reconstruction of shapes.
Another method also belonging to the area of fringe projection has been demonstrated, utilizing the
depth of field of the camera ((Univ. of Stuttgart)). It is also possible to use projected patterns
primarily as a means of structure insertion into scenes, for an essentially photogrammetric
acquisiton.
Precision and range
The optical resolution of fringe projection methods depends on the width of the stripes used and
their optical quality. It is of course also limited by the wavelength of light. An extreme reduction of
stripe width proves inefficient due to limitations in depth of field, camera resolution and display
resolution. Therefore the phase shift method has been widely established: A number of at least 3,
typically about 10 exposures are taken with slightly shifted stripes. The first theoretical deductions
of this method relied on stripes with a sine wave shaped intensity modulation, but the methods
works with "rectangular" modulated stripes, as delivered from LCD or DLP displays as well. By
phase shifting, surface detail of e.g. 1/10 the stripe pitch can be resolved. Current optical stripe
pattern profilometry hence allows for detail resolutions down to the wavelength of light, below 1
micrometer in practice or, with larger stripe patterns, to approx. 1/10 of the stripe width.
Concerning level accuracy, interpolating over several pixels of the acquired camera image can yield
a reliable height resolution and also accuracy, down to 1/50 pixel.
Arbitrarily large objects can be measured with accordingly large stripe patterns and setups. Practical
applications are documented involving objects several meters in size.
Typical accuracy figures are:
Planarity of a 2ft. (60cm) wide surface, to 10 m.
Shape of a motor combustion chamber to 2 m (elevation), yielding a volume accuracy 10
times better than with volumetric dosing.
Shape of an object 2" large, to about 1 m
Radius of a blade edge of e.g. 10 m, to 0.4 m

Navigation
As the method can measure shapes from one
perspective only at a time, complete 3D shapes
have to be combined from different measurements
in different angles. This can be accomplished by
attaching marker points to the object and
combining perspectives afterwards by matching
these markers. The process can be automated, by
mounting the object on a motorized turntable or
CNC positioning device. Markers can as well be
applied on a positioning device instead of the
object itself.
The 3D data gathered can be used to retrieve CAD
(computer aided design) data and models from
existing components (reverse engineering), hand formed samples or sculptures, natural objects or
artifacts.
Limitations
As with all optical methods,
reflective or transparent
surfaces raise difficulties.
Reflections are causing light
either being reflected away
from the camera or right into
its optics. In both cases, the
dynamic range of the camera
can be exceeded. Double
reflections can cause the stripe
pattern to be overlaid with
unwanted light, entirely
eliminating the chance for proper detection. Reflective cavities are therefore difficult to handle.
Transparent or semi transparent surfaces are also causing major difficulties. In these cases, coating
the surfaces with a thin opaque lacquer just for measuring purposes is a common practice. For
measuring entirely reflective surfaces, the alternative method of fringe reflection has been
implemented.
Speed
Although several patterns have to be taken per picture in most structured light variants, high speed
implementations are available for a number of applications, for example:
Inline precision inspection of components during the production process.
Health care applications, as live measuring of human body shapes or the micro structures of
human skin.
Motion picture applications have been proposed, for example the acquisition of spatial scene data
for three dimensional television.
Applications
Precision shape measurement for production control (e.g. turbine blades)
Reverse engineering (obtaining precision CAD data from existing objects)
Volume measurement (e.g. combustion chamber volume in motors)
Classification of grinding materials and tools
Precision structure measurement of grinded surfaces
Radius determination of cutting tool blades
Precision measurement of planarity
Documenting objects of cultural heritage
Skin surface measurement for cosmetics and medicine
Body shape measurement
Forensic inspections
Road pavement structure and roughness
Wrinkle measurement on cloth and leather
Measurement of topography of solar cells (see reference W J Walecki, et al. 2008)