面向智能制造的复杂型面全场三维光学精密测量技术研究

Intelligent manufacturing is the integration of information technology and manufacturing equipment. Achieving 3D design-measurement-manufacturing closed-loop process control is one of the symbols of the intelligent manufacturing. The technology challenge comes with it is how to achieve in-situ, high-speed and high-accuracy 3D measurement. The complexity of the workpiece's geometric structure and the diversity of workpiece's material lead to the data loss which results in the multi-reflection of highly reflective surfaces and the scattered light from translucent surfaces. Aiming at the world-class challenge of immeasurability of multi-reflection and translucent surfaces as well as the bottle-neck of high-speed 3D measurement, this proposal is on the basis of full-field dense fringe projection phase profilometry and establishes the fringe overlap model. The separation theory of multiple reflection light based on single pixel imaging and selective projection technology is proposed for the first time. The proposal also proposes the theory of 2-D multi-frequency projection and the high-accuracy 3D measurement method for the translucent surfaces and the test method of the PSF (point spread function) based on single pixel imaging. The full-field and full-depth of field mathematical model of the projection lens is established. The optimization among the measurement accuracy, full-field PSF and the fringe parameters is performed. The high-speed, high-accuracy projection and the measurability of 3D information of complex profiles are tackled. This has very important academic value and practical significance for realizing the integration of manufacturing and measurement of intelligent manufacturing.

智能制造是信息技术和制造装备的融合，标志之一是实现“三维设计-测量-加工”的闭环工艺调控，带来的技术难点是工件原位、高速、高精度的三维测量。工件几何形状的复杂性和材质的多样性，导致三维测量因强反光表面的多次反射和半透明表面的次表面散射而出现数据缺失。本项目以三维测量领域存在的多次反光/半透明表面的不可测性世界难题和高速三维测量技术瓶颈为研究目标，以获取全场密集点云的光栅相位法为基础，建立光栅条纹混叠模型，首次提出基于单像素成像的多次反射光混叠条纹分离理论和选择性投射技术；提出二维多频复合条纹投射理论和半透明表面高精度三维测量方法；提出基于单像素成像的点扩散函数测试方法，建立投影镜头全场全景深数学精确模型，实现测量精度、全场点扩散函数及投影条纹参数三者的优化，突破高速、高精度条纹投射技术，解决复杂型面三维信息的可测性问题，对实现“加工/测量”一体化的智能制造具有重要的学术价值和现实意义。

复杂型面全场三维光学精密测量技术中多次反射条件下全场三维测量、半透明材料高精度三维形貌测量和高速三维测量等理论和方法尚处于探索和研究阶段，研究并突破数字化、可在现场在线集成、适应各种材料复杂表面的快速精密测量理论和方法是精密测量技术的国际前沿发展方向之一。.本项目针对多次反射条件下的三维测量、半透明材料高精度形貌测量和高速三维测量等关键瓶颈问题，创新探索全局光照混叠机制，建立了并行单像素成像模型，实现了多次反光/半透明次表面散射光等全局混叠光的准确分离，成为全局光照分离的统一数学模型，为全局光照干扰下的三维重构提供了理论基础；针对工业制造的快速测量需求，采用了投影重构方法大幅提升了并行单像素成像效率，解决了并行单像素成像方法的实用性问题，极大满足了工业测量中的快速性与高精度的测量需求；针对次表面散射条件下的三维测量难题，分析了次表面散射光的混叠机理，提出了相位误差补偿模型，实现了半透明次表面散射条件下三维形貌测量；针对高速三维测量的应用需求，研究新型高速全场光栅条纹投射原理和方法，提出了投影镜头全场点扩散函数评测方法、基于投影散焦模糊的二值高速条纹投射优化方法和基于三角波投影的三维测量方法等，在保证测量效率的同时，提升测量精度、扩展高速测量景深。.本项目研制了系统原理样机，包括：多次反射条件下的自适应光栅相位三维测量系统，半透明材料高精度三维形貌测量系统，高速三维测量系统。设计并构建了结构光场三维测量系统，实现更高完整度的三维测量与重建。在该项目成果基础上，申请国家级项目2项，企业联合课题10余项，在航空航天、交通装备、发动机等先进制造领域，开展了航空结构件、复合材料件和发动机涡轮叶片等核心零部件的三维测量和智能数据分析工作，实现了技术成果的落地应用。.在执行项目期间，共发表论文34篇，其中SCI收录文章23篇，EI收录文章8篇；申请发明专利19项，其中7项获得授权。全部完成项目预期指标要求。