Zhou Zhilong, Shangguan Jinyong, Sun Xuemei, Liu Yunlong, Zhang Xu, Zhang Dengbo, Liu Haoran
College of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, China.
Sensors (Basel). 2025 Jul 27;25(15):4661. doi: 10.3390/s25154661.
Large-sized components with numerous small key local features are essential in advanced manufacturing. Achieving high-precision quality control necessitates accurate and highly efficient three-dimensional (3D) measurement techniques. A flexible measurement system integrating a fringe-projection-based 3D scanner with an industrial robot is developed to enable the rapid measurement of large object surfaces. To enhance overall measurement accuracy, we propose an enhanced calibration method utilizing a multidimensional ball-based calibrator to simultaneously calibrate for hand-eye transformation and robot kinematic parameters. Firstly, a preliminary hand-eye calibration method is introduced to compensate for measurement errors at observation points, leveraging geometric-constraint-based optimization and a virtual single point derived via the barycentric calculation method. Subsequently, a distance-constrained calibration method is proposed to jointly estimate the hand-eye transformation and robot kinematic parameters, wherein a distance error model is constructed to link parameter errors with the measured deviations of a virtual single point. Finally, calibration and validation experiments were carried out, and the results indicate that the maximum and average measurement errors were reduced from 1.053 mm and 0.814 mm to 0.421 mm and 0.373 mm, respectively, thereby confirming the effectiveness of the proposed method.
具有众多小尺寸关键局部特征的大型部件在先进制造中至关重要。实现高精度质量控制需要精确且高效的三维（3D）测量技术。开发了一种将基于条纹投影的3D扫描仪与工业机器人集成的灵活测量系统，以实现对大型物体表面的快速测量。为提高整体测量精度，我们提出一种增强的校准方法，利用基于多维球的校准器同时校准手眼变换和机器人运动学参数。首先，引入一种初步的手眼校准方法，通过基于几何约束的优化和经由重心计算方法导出的虚拟单点来补偿观测点处的测量误差。随后，提出一种距离约束校准方法来联合估计手眼变换和机器人运动学参数，其中构建距离误差模型以将参数误差与虚拟单点的测量偏差联系起来。最后，进行了校准和验证实验，结果表明最大测量误差和平均测量误差分别从1.053毫米和0.814毫米降至0.421毫米和0.373毫米，从而证实了所提方法的有效性。
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