Enhanced Calibration Method for Robotic Flexible 3D Scanning System
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-base...
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| Format: | Article |
| Language: | English |
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MDPI AG
2025-07-01
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| Series: | Sensors |
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| Online Access: | https://www.mdpi.com/1424-8220/25/15/4661 |
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| author | Zhilong Zhou Jinyong Shangguan Xuemei Sun Yunlong Liu Xu Zhang Dengbo Zhang Haoran Liu |
| author_facet | Zhilong Zhou Jinyong Shangguan Xuemei Sun Yunlong Liu Xu Zhang Dengbo Zhang Haoran Liu |
| author_sort | Zhilong Zhou |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-7117f1405f504df3ac5ec98f8ea2a541 |
| institution | Kabale University |
| issn | 1424-8220 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj-art-7117f1405f504df3ac5ec98f8ea2a5412025-08-20T03:36:30ZengMDPI AGSensors1424-82202025-07-012515466110.3390/s25154661Enhanced Calibration Method for Robotic Flexible 3D Scanning SystemZhilong Zhou0Jinyong Shangguan1Xuemei Sun2Yunlong Liu3Xu Zhang4Dengbo Zhang5Haoran Liu6College of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, ChinaCollege of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, ChinaCollege of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, ChinaCollege of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, ChinaCollege of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, ChinaCollege of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, ChinaCollege of Mechanical and Vehicle Engineering, Linyi University, Linyi 276012, ChinaLarge-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.https://www.mdpi.com/1424-8220/25/15/4661robotic 3D scanning systemhand-eye calibrationkinematic parameter calibrationgeometric constraintserror correction |
| spellingShingle | Zhilong Zhou Jinyong Shangguan Xuemei Sun Yunlong Liu Xu Zhang Dengbo Zhang Haoran Liu Enhanced Calibration Method for Robotic Flexible 3D Scanning System Sensors robotic 3D scanning system hand-eye calibration kinematic parameter calibration geometric constraints error correction |
| title | Enhanced Calibration Method for Robotic Flexible 3D Scanning System |
| title_full | Enhanced Calibration Method for Robotic Flexible 3D Scanning System |
| title_fullStr | Enhanced Calibration Method for Robotic Flexible 3D Scanning System |
| title_full_unstemmed | Enhanced Calibration Method for Robotic Flexible 3D Scanning System |
| title_short | Enhanced Calibration Method for Robotic Flexible 3D Scanning System |
| title_sort | enhanced calibration method for robotic flexible 3d scanning system |
| topic | robotic 3D scanning system hand-eye calibration kinematic parameter calibration geometric constraints error correction |
| url | https://www.mdpi.com/1424-8220/25/15/4661 |
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