基于视觉定位跟踪的大型机械部件数字化对接关键技术研究
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摘要
近年来,伴随着航空航天、汽车、造船等领域在大型机械部件设计与制造方面的自动化水平日益提高,数字化装配和对接已经成为大型机械部件制造中不可或缺的重要环节之一。在工业现场,通常利用光学测量技术及设备辅助完成大型机械部件自动、快速、准确的装配和对接。然而,我国在该领域的研究相对薄弱,与发达国家的先进水平仍存在较大差距。
本论文面向国内制造业中的大型机械部件数字化对接的实际需求,以国家自然科学基金和北京市自然科学基金等项目为依托,着重研究了基于视觉定位跟踪的大型机械部件数字化对接过程中若干关键技术与问题,并取得了以下成果：
(1)构建视觉定位跟踪系统。针对大型机械部件数字化对接装配体系的工作流程,构建视觉定位跟踪系统以获取待对接部件的完整3D轮廓信息。视觉定位跟踪系统主要可以分为前端测量子系统和后端跟踪子系统：前者主要采用彩色编码结构光测量,以获取局部密集型测量点云；而后者则基于双目立体视觉原理,通过实时定位跟踪前端测量摄像机的瞬时空间位姿,实现多视局部测量点云的自动、准确拼接。
(2)研究基于De Bruijn伪随机序列的彩色编码结构光技术。基于光学面-线三角法测量原理,利用5值3阶De Bruijn序列编码生成水平彩色条纹图案,针对于传统RGB解码算法的不足之处,提出了
一种HSI空间解码算法,通过将颜色分量与亮度分量的有效分离,实现条纹边界的亚像素定位。最后,利用两组对比实验得出下列结论：a)HSI空间解码算法明显优于传统RGB解码方法,能够完全分离颜色分量与亮度分量,避免了二者之间的相互干扰对测量精度的影响；b)与水平彩色光条图案相比,水平彩色条纹图案具有较高的分辨率,且二者的测量精度基本一致。
(3)建立坐标转换误差评价体系。针对机械部件数字化对接过程中广泛涉及的坐标转换问题,定义两种误差评价模型：转换点集-转换点集误差模型和转换点集-测试点集误差模型；详细分析了坐标值误差法、均方根误差法和相对欧氏距离误差法等3种误差评价方法,并利用理论推导证明相对欧氏距离误差法对于转换点集-测试点集误差模型的无效情况：即一旦测试点集位置固定,无论转换点集发生怎样的变化,相对欧氏距离误差参数值始终为一固定常数。
(4)提出一种特征标志点规划布局方法,确保在规定的测量空间范围内,合理布局尽可能少的转换点即可满足预先给定的精度要求。该方法主要涉及以下几个方面：根据特征标志点的分类,定义标志点布局参数可以分为点集内布局参数和点集间布局参数,前者主要包括点个数、基准点坐标和坐标差值,后者则提出了转换点集和测试点集之间的包络融合度概念；理论推导了标志点布局对坐标转换精度的影响；归纳、总结出一系列标志点规划布局指导原则；提出了一种基于曲率特征加权质心点约束的自适应标志点规划布局算法。利用计算机仿真实验和实际实验两种方式分别证明了标志点个数、分布形式、包络融合度等布局参数对坐标转换精度的影响以及相对欧氏距离误差法的无效情况。此外,分别采用测量控制场和3D点云精简两组实验对前面提出的自适应标志点规划布局算法进行了止确性和有效性验证。该方法可广泛适用十地理测绘、视觉测量、生物医学、机器人导航、多传感器融合等众多涉及坐标转换的实际工程领域,具有十分重要的研究意义和应用价值。
(5)研究测量点云数据与CAD设计模型之间的配准方法。将利用NURBS曲面表示的CAD模型均匀离散化,生成与测量点云具有相同数量级的离散模型点云。测量点云与离散模型点云之间的数据配准主要包括粗配准和精配准两个阶段。在粗配准阶段中,提出一种基于距离约束一致性的曲率特征粗配准算法,它主要根据曲率的刚体变换不变性,选取满足距离约束一致性原则的曲率特征点集作为基准,从而可以解算出两组点云之间的旋转矩阵和平移矢量；精配准阶段则设计一种基于网格四分搜索法的改进ICP精配准算法在每个点的对应邻域范围内,利用网格四分搜索法确定对应点到对应切平面之间的最小距离,即可实现两组点云之间的精配准。模拟实验和实际实验结果表明,这里提出的基于距离约束一致性的曲率特征粗配准算法能够达到较高的配准精度,可以为后续精配准工作提供可靠而有效的转换参数初值。
Recently, digital assembly and joining has already been one of indispensable parts for manufacturing large scale mechanical components thanks to the increasing level of automatic design and manufacture for mechanical components within several engineering fields, such as aerospace, automobile, and ship, etc. In practice, several optical measuring equipments and devices can be used to assist large scale mechanical components to assembly and join automatically, fast and accurately. However, domestic research on digital assembly and joining is still relatively weak and far away from the advanced technology of developed countries.
To satisfy the requirement of digital joining for large scale mechanical components in the manufacturing industry, this dissertation has been supported by both National Natural Science Foundation and Beijing Natural Science Foundation, which focuses on few key technologies and issues of digital joining for mechanical components based on visual positioning and tracking. There are5achievements as following:
(1) A visual positioning and tracking system is built. In the process of digital joining mechanical components, the visual positioning and tracking system can be used to acquire entirely3D profile of every component, which can be divided into a front measuring subsystem and a rear tracking subsystem. The former is applied to obtain local intensive point cloud by color-encoded structured light; according to the principle of stereo vision, the latter needs to complete automatic and accurate registration among different groups of point cloud by tracking positions and orientations of front cameras.
(2) Based on De Bruijn sequence, color-encoded structured light is further studied. In accordance with optical plane-line triangulation, a color horizontal stripes pattern has been encoded by a De Bruijn sequence of order3over5color symbols. To avoid the drawback of traditional RGB algorithm, a HSI decoding algorithm has been developed to separate color values from intensity values effectively for locating edges of stripes with sub-pixel accuracy. Experimental results have shown that:a) Results from HSI decoding algorithm are better than that of RGB algorithm by isolating color values from intensity values, which ensures that the accuracy will not be affected by both mutual disturbance; b) Compared with the color horizontal slits pattern, the color horizontal stripes pattern can acquire higher resolution with similar accuracy.
(3) An error evaluating system for coordinate transformation is established. Aiming to coordinate transformation involved in digital joining for mechanical components, both calculating sets-testing sets error evaluating model and calculating sets-calculating sets error evaluating model are defined; and3evaluating approaches e.g. the coordinate error method, RMS error method and the error method of relative Euclidean distance are analyzed in details; besides, an invalid case of the third evaluating method is proved that once testing set has been determined, error parameters is always a constant no matter what variation calculating set does.
(4) An efficient approach for planning geometrical distribution of markers is proposed to ensure that planning a reasonable distribution of markers as few as possible within a known3D space will satisfy a given accuracy requirement. The approach mainly contains the following aspects:according to the classification of markers, distribution parameters is described by internal parameter and external parameter. The former is composed of point number, the coordinates of reference point and the coordinate difference, and the latter is defined as the overlapping degree between calculating set and testing set; influence of geometrical distribution of markers to transformation accuracy is formulated; subsequently, a guideline for planning geometrical distribution of markers is generalized and summarized; consequently, an adaptive algorithm for planning geometrical distribution of markers is presented based on a constraint of centroid with curvature weighted coefficients. Both computer simulating experiment and practical experiment have been used to prove influence of distribution parameters of markers to transformation accuracy and invalidation of the error method of relative Euclidean distance. Moreover, the adaptive algorithm has been verified to be correct and valid by measuring controlling field experiment and3D point cloud simplification experiment. With significance and application value, the proposed approach is suitable to solve coordinate transformation involved in several practical engineering fields, such as geological survey, vision measurement, biomechanics, robotic navigation, and multi-sensor fusion, etc.
(5) Registration between measuring point cloud and CAD model is researched. Similar to point number of measuring point cloud, a discrete model point cloud can be generated through uniformly segmenting CAD model represented by NURBS surface. Registration between both groups of point cloud should be divided into coarse registration and fine registration. In the first stage, a coarse registration algorithm is presented based on a consistent distance constraint and a curvature invariant characteristic of rigid transformation, where a curvature point set is chosen to be invariant to calculate a rotation matrix and a translation vector. Subsequently, a proved ICP fine registration algorithm based on grid quartering searching method is designed by determining a least distance between a point and its corresponding tangent plane. Both simulating experiment and practical experiment has illustrated that the coarse registration algorithm can achieve higher accuracy and provide reliable initial values for the fine registration.
本论文面向国内制造业中的大型机械部件数字化对接的实际需求,以国家自然科学基金和北京市自然科学基金等项目为依托,着重研究了基于视觉定位跟踪的大型机械部件数字化对接过程中若干关键技术与问题,并取得了以下成果：
(1)构建视觉定位跟踪系统。针对大型机械部件数字化对接装配体系的工作流程,构建视觉定位跟踪系统以获取待对接部件的完整3D轮廓信息。视觉定位跟踪系统主要可以分为前端测量子系统和后端跟踪子系统：前者主要采用彩色编码结构光测量,以获取局部密集型测量点云；而后者则基于双目立体视觉原理,通过实时定位跟踪前端测量摄像机的瞬时空间位姿,实现多视局部测量点云的自动、准确拼接。
(2)研究基于De Bruijn伪随机序列的彩色编码结构光技术。基于光学面-线三角法测量原理,利用5值3阶De Bruijn序列编码生成水平彩色条纹图案,针对于传统RGB解码算法的不足之处,提出了
一种HSI空间解码算法,通过将颜色分量与亮度分量的有效分离,实现条纹边界的亚像素定位。最后,利用两组对比实验得出下列结论：a)HSI空间解码算法明显优于传统RGB解码方法,能够完全分离颜色分量与亮度分量,避免了二者之间的相互干扰对测量精度的影响；b)与水平彩色光条图案相比,水平彩色条纹图案具有较高的分辨率,且二者的测量精度基本一致。
(3)建立坐标转换误差评价体系。针对机械部件数字化对接过程中广泛涉及的坐标转换问题,定义两种误差评价模型：转换点集-转换点集误差模型和转换点集-测试点集误差模型；详细分析了坐标值误差法、均方根误差法和相对欧氏距离误差法等3种误差评价方法,并利用理论推导证明相对欧氏距离误差法对于转换点集-测试点集误差模型的无效情况：即一旦测试点集位置固定,无论转换点集发生怎样的变化,相对欧氏距离误差参数值始终为一固定常数。
(4)提出一种特征标志点规划布局方法,确保在规定的测量空间范围内,合理布局尽可能少的转换点即可满足预先给定的精度要求。该方法主要涉及以下几个方面：根据特征标志点的分类,定义标志点布局参数可以分为点集内布局参数和点集间布局参数,前者主要包括点个数、基准点坐标和坐标差值,后者则提出了转换点集和测试点集之间的包络融合度概念；理论推导了标志点布局对坐标转换精度的影响；归纳、总结出一系列标志点规划布局指导原则；提出了一种基于曲率特征加权质心点约束的自适应标志点规划布局算法。利用计算机仿真实验和实际实验两种方式分别证明了标志点个数、分布形式、包络融合度等布局参数对坐标转换精度的影响以及相对欧氏距离误差法的无效情况。此外,分别采用测量控制场和3D点云精简两组实验对前面提出的自适应标志点规划布局算法进行了止确性和有效性验证。该方法可广泛适用十地理测绘、视觉测量、生物医学、机器人导航、多传感器融合等众多涉及坐标转换的实际工程领域,具有十分重要的研究意义和应用价值。
(5)研究测量点云数据与CAD设计模型之间的配准方法。将利用NURBS曲面表示的CAD模型均匀离散化,生成与测量点云具有相同数量级的离散模型点云。测量点云与离散模型点云之间的数据配准主要包括粗配准和精配准两个阶段。在粗配准阶段中,提出一种基于距离约束一致性的曲率特征粗配准算法,它主要根据曲率的刚体变换不变性,选取满足距离约束一致性原则的曲率特征点集作为基准,从而可以解算出两组点云之间的旋转矩阵和平移矢量；精配准阶段则设计一种基于网格四分搜索法的改进ICP精配准算法在每个点的对应邻域范围内,利用网格四分搜索法确定对应点到对应切平面之间的最小距离,即可实现两组点云之间的精配准。模拟实验和实际实验结果表明,这里提出的基于距离约束一致性的曲率特征粗配准算法能够达到较高的配准精度,可以为后续精配准工作提供可靠而有效的转换参数初值。
Recently, digital assembly and joining has already been one of indispensable parts for manufacturing large scale mechanical components thanks to the increasing level of automatic design and manufacture for mechanical components within several engineering fields, such as aerospace, automobile, and ship, etc. In practice, several optical measuring equipments and devices can be used to assist large scale mechanical components to assembly and join automatically, fast and accurately. However, domestic research on digital assembly and joining is still relatively weak and far away from the advanced technology of developed countries.
To satisfy the requirement of digital joining for large scale mechanical components in the manufacturing industry, this dissertation has been supported by both National Natural Science Foundation and Beijing Natural Science Foundation, which focuses on few key technologies and issues of digital joining for mechanical components based on visual positioning and tracking. There are5achievements as following:
(1) A visual positioning and tracking system is built. In the process of digital joining mechanical components, the visual positioning and tracking system can be used to acquire entirely3D profile of every component, which can be divided into a front measuring subsystem and a rear tracking subsystem. The former is applied to obtain local intensive point cloud by color-encoded structured light; according to the principle of stereo vision, the latter needs to complete automatic and accurate registration among different groups of point cloud by tracking positions and orientations of front cameras.
(2) Based on De Bruijn sequence, color-encoded structured light is further studied. In accordance with optical plane-line triangulation, a color horizontal stripes pattern has been encoded by a De Bruijn sequence of order3over5color symbols. To avoid the drawback of traditional RGB algorithm, a HSI decoding algorithm has been developed to separate color values from intensity values effectively for locating edges of stripes with sub-pixel accuracy. Experimental results have shown that:a) Results from HSI decoding algorithm are better than that of RGB algorithm by isolating color values from intensity values, which ensures that the accuracy will not be affected by both mutual disturbance; b) Compared with the color horizontal slits pattern, the color horizontal stripes pattern can acquire higher resolution with similar accuracy.
(3) An error evaluating system for coordinate transformation is established. Aiming to coordinate transformation involved in digital joining for mechanical components, both calculating sets-testing sets error evaluating model and calculating sets-calculating sets error evaluating model are defined; and3evaluating approaches e.g. the coordinate error method, RMS error method and the error method of relative Euclidean distance are analyzed in details; besides, an invalid case of the third evaluating method is proved that once testing set has been determined, error parameters is always a constant no matter what variation calculating set does.
(4) An efficient approach for planning geometrical distribution of markers is proposed to ensure that planning a reasonable distribution of markers as few as possible within a known3D space will satisfy a given accuracy requirement. The approach mainly contains the following aspects:according to the classification of markers, distribution parameters is described by internal parameter and external parameter. The former is composed of point number, the coordinates of reference point and the coordinate difference, and the latter is defined as the overlapping degree between calculating set and testing set; influence of geometrical distribution of markers to transformation accuracy is formulated; subsequently, a guideline for planning geometrical distribution of markers is generalized and summarized; consequently, an adaptive algorithm for planning geometrical distribution of markers is presented based on a constraint of centroid with curvature weighted coefficients. Both computer simulating experiment and practical experiment have been used to prove influence of distribution parameters of markers to transformation accuracy and invalidation of the error method of relative Euclidean distance. Moreover, the adaptive algorithm has been verified to be correct and valid by measuring controlling field experiment and3D point cloud simplification experiment. With significance and application value, the proposed approach is suitable to solve coordinate transformation involved in several practical engineering fields, such as geological survey, vision measurement, biomechanics, robotic navigation, and multi-sensor fusion, etc.
(5) Registration between measuring point cloud and CAD model is researched. Similar to point number of measuring point cloud, a discrete model point cloud can be generated through uniformly segmenting CAD model represented by NURBS surface. Registration between both groups of point cloud should be divided into coarse registration and fine registration. In the first stage, a coarse registration algorithm is presented based on a consistent distance constraint and a curvature invariant characteristic of rigid transformation, where a curvature point set is chosen to be invariant to calculate a rotation matrix and a translation vector. Subsequently, a proved ICP fine registration algorithm based on grid quartering searching method is designed by determining a least distance between a point and its corresponding tangent plane. Both simulating experiment and practical experiment has illustrated that the coarse registration algorithm can achieve higher accuracy and provide reliable initial values for the fine registration.
引文
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