Patent Grant
9677877
The present invention relates to a non-contact measurement system and, in particular, to a structured-light, three-dimensional (3D) scanning system that may be used for measuring the dimensions of objects.
3D scanning systems (i.e., 3D scanners) are systems that can sense a physical object (e.g., detect the range/distance of surfaces) in order to obtain information about the object's shape. 3D scanners may be used for a variety of purposes. 3D scanners may serve as the interface between a human and a computing system (e.g., game console). 3D scanners may also be used to create 3D computer models (e.g., scene restoration). In addition, 3D scanners are important for the non-contact, automatic measurement of dimensions that is often required in industry. For example, 3D scanners are used in the shipping/freight industry to help compute dimensional weight and calculate shipping costs.
3D scanners may use a variety of technologies to sense a physical object. Optical sensing is desirable in many circumstances because no physical contact with the object is required. A structured-light 3D scanner projects a pattern of light (i.e., light pattern) into a field of view. Distortions to the light pattern caused by an object in the field of view are imaged and analyzed to create a range image, in which each pixel has a value that correlates with range (i.e., the distance from the 3D scanner to a surface). The range image may be analyzed to obtain the dimensions of the object.
It is common to use a fixed-position, structured-light 3D scanner to measure objects that vary in range and in size. Projecting a single light pattern imposes limitations on the objects that may be dimensioned. These limitations may prevent the dimensioning of some objects and/or may slow the dimensioning process (e.g., by requiring some adjustment). What is more, users of such systems may require training to handle these limitations, thereby undermining the 3D scanner's advantages of simplicity and automation.
A need exists for a 3D scanner that can dimension a wide variety objects by automatically sensing and adapting to the different scanning requirements for each object (e.g., range, size, etc.).
Accordingly, in one aspect, the present invention embraces a dual-projector 3D scanner. The 3D scanner includes a structured-light projection subsystem having two projectors: a first projector and a second projector. The projectors are each configured to project a particular light pattern onto an object. The first projector projects a first light pattern, and the second projector projects a second light pattern. The 3D scanner further includes a camera for capturing images of either light pattern reflected from an object. A computing-and-control subsystem that is communicatively coupled to the structured-light projection subsystem and the camera enables the 3D scanner to obtain information regarding the object's size/shape through a number of process steps. First, the object's scanning requirements are obtained. Next, based on the scanning requirements, either the first or the second projector is activated, and a pattern image is captured using the camera. The resulting pattern image is then processed to produce a range image.
In an exemplary embodiment of the dual-projector 3D scanner, the computing-and-control subsystem is configured to analyze the range image to obtain the object's dimensions.
In an exemplary embodiment of the dual-projector 3D scanner, the first light-pattern's pattern-feature density is lower than the second light-pattern's pattern-feature density.
In another exemplary embodiment of the dual-projector 3D scanner, the first light-pattern's optical intensity is lower than the second light-pattern's optical intensity.
In another exemplary embodiment of the dual-projector 3D scanner, the first projector's field of view is smaller than the second projector's field of view.
In another exemplary embodiment of the dual-projector 3D scanner, the object's scanning requirements include the object's size.
In another exemplary embodiment of the dual-projector 3D scanner, the object's scanning requirements include the object's size, and the first projector is activated when the object's size is less than about 1 cubic centimeter, while the second projector is activated when the object's size is greater than about 1 cubic meter.
In another exemplary embodiment of the dual-projector 3D scanner, the object's scanning requirements include the object's range.
In another exemplary embodiment of the dual-projector 3D scanner, the object's scanning requirements include the object's range, and the first projector is activated when the object's is within a range of about 0.5 meter to about 2 meters, while the second projector is activated when the object's is within a range of about 2 meters to about 4 meters.
In another aspect, the present invention embraces a method for dimensioning an object using a dual-projector three-dimensional (3D) scanner. The method includes activating one of the 3D scanner's two projectors to project a light pattern onto the object. Next, the camera is used to capture a preliminary pattern image. At least a portion of the preliminary pattern image is then analyzed, and based on the analysis, one of the 3D scanner's two projectors is selected. The object is then dimensioned using the selected projector.
In an exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the object is dimensioned by: (i) activating the selected camera, (ii) capturing a pattern image using the camera, (iii) generating a range image from the pattern image, and (iv) deriving the object's dimensions from the range image.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the analysis of the preliminary pattern image includes determining the object's range.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the analysis of the preliminary pattern image includes determining the object's size.
In another aspect, the present invention embraces a method for dimensioning an object using a dual-projector three-dimensional (3D) scanner. The method starts with activating a first projector to project a first light pattern onto the object. Next, a camera is used to capture a first pattern image of the first light pattern reflected from the object. Next, a second projector is activated to project a second light pattern onto the object, and a second pattern image of the second light pattern reflected from the object is captured. The first pattern image and the second pattern image are evaluated and, based on the evaluation, either the first pattern image or the second pattern image is selected. Finally, the object is dimensioned using the selected pattern image.
In an exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the object is dimension by generating a range image using the selected pattern image and then using the range image to derive the object's dimensions.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the first pattern image and the second pattern image are evaluated by detecting that, at least a portion of, the first pattern image or the second pattern image is saturated.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the first pattern image and the second pattern image are evaluated by detecting that the intensity of pattern features, in either the first pattern image or the second pattern image, is too low for dimensioning.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the first pattern image and the second pattern image are evaluated by detecting that the density of pattern features, in either the first pattern image or the second pattern image, is too high or too low for dimensioning at or above a particular accuracy.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the first light pattern's pattern-feature density is lower than the second light pattern's pattern-feature density.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the first light pattern's optical intensity is lower than the second light pattern's optical intensity.
In another exemplary embodiment of the method for dimensioning an object using a dual-projector three-dimensional (3D) scanner, the first projector's field of view is smaller than the second projector's field of view.
The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.
The present invention embraces a 3D scanner, which may be used for a variety of purposes including dimensioning. Many different technologies may be used for 3D scanning. The present invention embraces a non-contact, active 3D-scanner that projects an optical pattern (i.e., structured light) onto an object and records the reflected pattern as a pattern image captured by a digital camera.
The 3D scanner obtains depth information (i.e., range) through the use of a stereoscopically arranged projector and camera. During a range measurement, the projector projects a known light pattern onto a surface. The camera captures an image (i.e., pattern image) of the light pattern reflected from the object. The reflected pattern will be spatially offset from the known pattern by an amount correlating with the range of the reflecting object. Analyzing the pattern image for range can be performed pixel-by-pixel in order to create a range image of the camera's field of view. Each pixel in the range image has a grey scale value that correlates with range. This range image may be analyzed to derive the dimensions of an object placed in the field of view of the 3D scanner.
The 3D scanner's projector projects a light pattern (i.e., pattern) that has a plurality of pattern elements (i.e., pattern features). Pattern features may be regularly spaced (e.g., grid) or randomly spaced. Pattern features may be discreet (e.g., dots) or continuous (e.g., lines). Pattern features may form repeated patterns or may be located randomly. Pattern features may be distributed over the projected field of view uniformly or non-uniformly. Pattern features may be identically sized, sized according to a group of sizes, or each sized differently. Unless otherwise stated, the present disclosure describes an exemplary embodiment in which the pattern features are light spots (i.e., dots) that have a similar shape/size and that are randomly distributed over the projected field of view.
When an object is placed in front of the 3D scanner, it reflects all or some of the projected light pattern. The portion of the light pattern reflected is determined by the 3D scanner's projector, the object's size, and the object's range. Dimensioning precision/accuracy corresponds to the number of dots reflected from the object (i.e., pattern-feature density). Typically, it is important to insure that an object reflects a sufficient number of dots and that these dots can be imaged accurately by a camera.
Problems with dimensioning can occur when the projected light pattern is not optimal for an object having a particular size positioned and positioned at a particular distance from the 3D scanner. A 3D scanner that projects one pattern may not be able to dimension accurately in all cases.
A pattern image of the object located at position “A” 4 will have more reflected dots (i.e., higher pattern-feature density) than a pattern image of the object located at position “B” 5 because the object intersects more of the projected pattern's field of view 6. Since the field of view spreads with range, an object placed too close to the 3D scanner may have areas that do not intersect with the projected pattern. In this case, a light pattern with a larger field of view could help dimensioning. Alternatively, objects placed too far from the 3D scanner may intersect with the projected pattern insufficiently to allow for accurate dimensioning. In this case, a light pattern having a smaller field of view could help dimensioning.
The dots in the pattern image of an object in position “A” will appear larger than the dots in the pattern image of an object located at position “B” because the object at position “A” is closer to the 3D scanner's camera. Objects placed too far from the 3D scanner may have reflected light patterns that are too small to be resolved by the camera (i.e., pixel sampling errors). In this case, a light pattern with larger dots and/or with greater dot spacing could help dimensioning.
The image intensity (i.e., pixel values) of the dots at position “A” will be higher than the image intensity of the dots at position “B” because the object is closer to the 3D scanner. An object placed too close to the 3D scanner, may have dot image intensities that saturate the camera and cause artifacts (e.g., pixel blooming). In this case, a light pattern with a lower intensity could help dimensioning. Objects placed too far from the 3D scanner, may have dot image intensities that are low and do not rise above the noise in the camera's sensor/electronics (i.e., poor signal-to-noise-ratio (SNR)). In this case, a light pattern having a higher intensity could help dimensioning.
The discussion so far has focused on an object having a particular size that is positioned both near and far. Similar dimensioning problems may also exist for large and small objects located a particular range. For example, a large object will intersect more of the projected light pattern at a particular range than a small object at the same position and, therefore, may require a larger projected light pattern field of view. Many possibilities exist because both range and object size variations must be accommodated by a 3D scanner.
In some cases, a user may remedy dimensioning problems (e.g., low accuracy, no results, etc.) by repositioning the object and/or 3D scanner. For example, a small object initially placed far from the 3D scanner may be moved closer to improve dimensioning (e.g., accuracy). Requiring the user to make adjustments or understand the limitations of the scanner is not always desirable, and sometimes it is impossible to make the necessary adjustments due to size and space limitations. Instead, the present invention embraces a system and method for accommodating the size/range limitations of a 3D scanner automatically by adjusting the projected pattern to suit the size/range of an object.
A block diagram of a dual-projector 3D scanner for dimensioning (i.e., scanner or dimensioner) according to an embodiment of the present invention is shown in
The first projector 11 projects a first light pattern and the second projector projects 12 a second light pattern. The first and second light pattern may be different in a variety of ways. For example, at a particular range, the first light pattern's field of view 13 (i.e., spatial extent of the light pattern) may be smaller than the second light pattern's field of view 14. In another exemplary embodiment, the first light pattern's pattern-feature density (e.g., the number of dots in the field of view) may be lower than the second light pattern's pattern-feature density (e.g., dot density). In another exemplary embodiment, the first light pattern's optical intensity (e.g., optical power per dot) may be lower than the second light-pattern's optical intensity. Other differences between the first and second light patterns may include (but are not limited to) pattern-feature size, pattern-feature shape, pattern-feature type (e.g., dot, line, etc.), pattern-feature arrangement (e.g., spacing, regularity, etc.), pattern-feature distribution, angular divergence, wavelength, and/or polarization.
A camera 15 captures a pattern image using a focusing element (e.g., lens, pinhole, etc.), which forms a real image of the reflected light pattern onto an image sensor. In some embodiments, the camera may include a filter (e.g., infrared filter), which passes the light pattern while blocking other (e.g., ambient) light from reaching the sensor. The camera's image sensor may convert the real image into an electronic signal using a plurality of light sensitive elements arranged in a contiguous array, wherein each light sensitive element samples a portion of the camera's field of view 16. The image sensor may use a variety of technologies to convert light into electronic signals (e.g., charge coupled device (i.e., CCD) technology, complementary metal oxide semiconductor (i.e., CMOS) technology, etc.). Conditioning electronics (e.g., analog-to-digital converters, clocks, amplifiers, digital signal processor, etc.) may be included as part of the camera and used to facilitate the formation of a digital image.
A computing-and-control subsystem 17 is communicatively coupled to the first projector 11, the second projector 12, and the camera 15. The computer-and-control subsystem 17 synchronizes operation/timing of the projectors and the camera (e.g., so that only one projector is on when camera captures a pattern image). The computer-and-control subsystem 17 may also control the camera's settings (e.g. focus, exposure). These settings may be adjusted to correspond with the activated projector, the object, and/or the environment (e.g., range, ambient lighting, etc.)
The computing-and-control subsystem 17 may include one or more processors 41 (e.g., one or more controller, digital signal processor (DSP), application specific integrated circuit (ASIC), programmable gate array (PGA), programmable logic controller (PLC), etc.). The processor 18 may be configured by processor-executable instructions (e.g., software) stored in at least one non-transitory storage medium (i.e., memory) 19 (e.g., read-only memory (ROM), flash memory, a hard-drive, etc.). The processor-executable instructions, when executed by the processor 18, configure the 3D scanner to obtain the object's scanning requirements (e.g., object size/range) and choose either the first or the second projector based on these requirements. The 3D scanner is then triggered to capture a pattern image, which is then processed by the processor to produce a range image. The range image is then analyzed by the processor to obtain the object's dimensions. The results of the processing and/or analysis may be stored in the computing-and-control's memory 19.
An exemplary embodiment of a method for dimensioning an object using the dual-projector 3D scanner is shown in
The preliminary pattern image is analyzed 22 (e.g., by the processor configured by software stored in the memory to perform image analysis algorithms). The results of the analysis include information to facilitate the selection of one of the two projectors for dimensioning. This information may be related to the object's range/size, the pattern quality (e.g., saturation, low signal, object coverage, etc.), or dimensioning accuracy (e.g., pattern-feature density). Based on the analysis, one of the 3D scanner's two projectors is selected 23 for dimensioning 24.
Dimensioning begins with activating the selected projector 25 to project a light pattern onto the object. A pattern image of the reflected light pattern is captured by the camera 26. The pattern image is processed by the processor to generate a range image 27. Algorithms running on the processor analyze the range image to derive the dimension of the object 28. These algorithms may also provide the precision and/or accuracy of these measurements. In some cases, the algorithms may return a measurement error when the accuracy of the dimensioning is not within a certain accuracy/precision or when no result can be computed.
Another exemplary embodiment of a method for dimensioning an object using the dual-projector 3D scanner is shown in
Another exemplary embodiment of a method for dimensioning an object using the dual-projector 3D scanner is shown in
Another exemplary embodiment of a method for dimensioning an object using the dual-projector 3D scanner is shown in
In summary, the purpose of utilizing two projectors in the 3D scanner is to expand the working limit of the 3D scanner and thus enhance its performance. To this end, aspects of the following may be changed: the projected pattern (e.g., type, angular resolution, feature size, field of view, intensity, wavelength, projection direction, etc.); the camera's settings for a particular projector (e.g., frame rate, resolution, etc.); and the physical arrangement of the camera and each projector (e.g., projector/camera spacing, projector/camera orientation, etc.). The present invention envisions any combination of these aspect variations to enhance 3D scanning performance.
To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:
In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.
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| European Extended search report in related EP Application No. 15190306.9, Dated Sep. 9, 2016, 15 pages [only new references are cited; remaining references were cited with partial search report in same application dated May 6, 2016]. |
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| European extended Search report in related EP Application 13785171.3, dated Sep. 19, 2016, 8 pages. |
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| European Search Report in related EP Application No. 15190315.0, Dated Apr. 1, 2016, 7 pages [Commonly owned Reference 2014/0104416 has been previously cited]. |
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| European Extended Search Report in related EP Application No. 16190017.0, dated Jan. 4, 2017, 6 pages. |
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| Thorslab, Examiner Cited NPL in Advisory Action dated Apr. 12, 2017 in related commonly owned application, downloaded from https://www.thorlabs.com/newgrouppage9.cfm?objectgroup—id=6430, 4 pages. |
| Eksma Optics, Examineer Cited NPL in Advisory Action dated Apr. 12, 2017 in related commonly owned application, downloaded from http://eskmaoptics.com/optical-systems/f-theta-lenses/f-theta-lens-for-1064-nm/, 2 pages. |
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| Number | Date | Country | |
|---|---|---|---|
| 20160377417 A1 | Dec 2016 | US |
