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Development of a Wide Area 3D Scanning System with a Rotating Line Laser

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sensors Article Development of a Wide Area 3D Scanning System with a Rotating Line Laser Jaeho Lee 1,†, Hyunsoo Shin 1,† and Sungon Lee 2,* 1 Department of Electrical and Electronic Engineering, Hanyang University, Ansan 15588, Korea; [email protected] (J.L.); [email protected] (H.S.) 2 School of Electrical Engineering, Hanyang University, Ansan 15588, Korea * Correspondence: [email protected]; Tel.: +82-31-400-5174 † These authors contributed equally to this work. Abstract: In a 3D scanning system, using a camera and a line laser, it is critical to obtain the exact geometrical relationship between the camera and laser for precise 3D reconstruction. With existing depth cameras, it is difficult to scan a large object or multiple objects in a wide area because only a limited area can be scanned at a time. We developed a 3D scanning system with a rotating line laser and wide-angle camera for large-area reconstruction. To obtain 3D information of an object using a rotating line laser, we must be aware of the plane of the line laser with respect to the camera coordinates at every rotating angle. This is done by estimating the rotation axis during calibration and then by rotating the laser at a predefined angle. Therefore, accurate calibration is crucial for 3D reconstruction. In this study, we propose a calibration method to estimate the geometrical relationship between the rotation axis of the line laser and the camera. Using the proposed method, we could accurately estimate the center of a cone or cylinder shape generated while the line laser was rotating. A simulation study was conducted to evaluate the accuracy of the calibration. In the experiment, we compared the results of the 3D reconstruction using our system and a commercial depth camera. The results show that the precision of our system is approximately 65% higher for plane reconstruction, Citation: Lee, J.; Shin, H.; Lee, S. and the scanning quality is also much better than that of the depth camera. Development of a Wide Area 3D Scanning System with a Rotating Line Keywords: 3D reconstruction; laser-camera calibration; triangulation Laser. Sensors 2021, 21, 3885. https:// doi.org/10.3390/s21113885 Academic Editor: Bijan Shirinzadeh 1. Introduction Today, many application fields require technology for 3D modeling of real-world Received: 6 May 2021 objects, such as design and construction of augmented reality (AR), quality verification, Accepted: 1 June 2021 Published: 4 June 2021 the restoration of lost CAD data, heritage scanning, surface deformation tracking, 3D reconstruction for object recognition and so on [1–7]. Among the non-contact scanning Publisher’s Note: MDPI stays neutral methods, the method using a camera and a line laser is widely used because the scanning with regard to jurisdictional claims in speed is relatively fast and there is no damage to the object [8,9]. There are two methods published maps and institutional affil- for measuring the distance with the laser: the laser triangulation (LT) method and the iations. time-of-flight (ToF) method. The LT method is slower but it has more precise results than the ToF method [10]. However, both methods have relatively small measurable zones. They scan a point or a line, at most, a narrow region at a time. A laser range finder (LRF) was developed to overcome this limitation. It extends the scan area by rotating the light source [11]. The scan area can be further increased by rotating the LRF. Recently, various Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland. methods for estimating the rotation axis of the LRF have been studied to obtain a 3D depth This article is an open access article map of the environment [12–22]. distributed under the terms and In this study, an LT system with a rotating line laser and wide-angle camera was conditions of the Creative Commons proposed as shown in Figure1. We only rotate the line laser, not the entire system, to scan a Attribution (CC BY) license (https:// wide area. Rotating a laser is easy because the line laser is light, leading to a simple system. creativecommons.org/licenses/by/ We do not need to rotate the camera because it already has a wide field of view with a 4.0/). proper lens (e.g., fish-eye lens). Sensors 2021, 21, 3885. https://doi.org/10.3390/s21113885 https://www.mdpi.com/journal/sensors Sensors 2021, 21, x FOR PEER REVIEW 2 of 14 Sensors 2021, 21, 3885 2 of 14 system. We do not need to rotate the camera because it already has a wide field of view withWith a proper this lens setup, (e.g the., fish first-eye step lens). is to precisely estimate this rotation axis with respect to theWith camera this setup coordinates,, the first step to measure is to precisely the depth estimate of anthis object rotation using axis with triangulation respect to [23]. Owingthe camera to various coordinates reasons,, to measure such asthe the dep fabricationth of an object error using of triangulation mechanical parts,[23]. Owing linelaser misalignmentto various reasons to the, such rotation as the axis, fabrication line laser error optical of mechanical properties, parts, and line so on, laser the misalign- rotation axis ofment the to line the laser rotation is somewhat axis, line laser different optical from propert the idealies, and CAD so on design., the rotation However, axis thisof the axis is preciselyline laser is measured somewhat to different obtain accuratefrom the 3Dideal information CAD design. from However, the LT this method. axis is precisely In this paper, wemeasured propose to a obtain novel calibrationaccurate 3D between information the camerafrom the coordinate LT method system. In this and paper the, rotatingwe pro- line laserpose coordinatea novel calibration system between using a the cone camera model. coordinat Findinge system the axis and of the rotation rotating with line respect laser to thecoordinate camera system coordinate using system a cone is model the key. Finding for accurate the axis calibration. of rotation We with noticed respect that to thethe cone shapecamera is coordinate always created system while is the the key plane for accurate of the line calibration. laser rotates We aboutnoticed the that rotation the cone axis of theshape motor is always due to created inevitable while imperfect the plane of alignment the line laser between rotate thes about line the laser rotation and the axis rotating of axis.the motor Therefore, due to we inevitable estimate imperfect the axis ofalignment rotation between using the the cone linemodel laser and because the rotating the central axis. Therefore, we estimate the axis of rotation using the cone model because the central axis of the cone and the rotation axis of the motor are same. The cone model enables us to axis of the cone and the rotation axis of the motor are same. The cone model enables us to estimate the rotation axis accurately leading to improved calibration results. In summary, estimate the rotation axis accurately leading to improved calibration results. In summary, our contribution is to propose a cone model for an accurate calibration between the camera our contribution is to propose a cone model for an accurate calibration between the cam- and the rotating line laser resulting in an accurate and wide 3D scanning system. era and the rotating line laser resulting in an accurate and wide 3D scanning system. Figure 1. Three dimensional (3D) reconstruction using our system, (a) setup of the system, (b) recon- Figure 1. Three dimensional (3D) reconstruction using our system, (a) setup of the system, (b) re- structionconstruction results. results. TheThe rest of of Section Section 11 definesdefines the the notation notation and and coordinate coordinate system, system, and and Section Section 2 intro-2 intro- ducesduces the schematic diagram diagram of of the the system system and and the the calibration calibration process. process. In Section In Section 3, the3, the triangulationtriangulation method method through through the the line line-plane-plane intersection intersection is described, is described, andand the calibration the calibration betweenbetween the fixed fixed line line laser laser and and camera, camera, and and the the calibration calibration between between the rotating the rotating line laser line laser andand cameracamera are explained. explained. In In Section Section 4,4 the, the calibration calibration accuracy accuracy according according to the to therotation rotation axisaxis ofof the line laser laser is is evaluated, evaluated, and and the the 3D 3D reconstruction reconstruction results results of the of theRGB RGB-D-D camera camera andand thisthis system are are compared. compared. Then, Then, the the accuracy accuracy of ofthe the 3D 3Ddepth depth estimation estimation is analyzed is analyzed usingusing a planar model. model. Finally, Finally, the the conclusions conclusions are are presented presented in Section in Section 5. 5. 2.2. OverallOverall System 2.1.2.1. HardwareHardware OurOur scanning system system has has a aline line laser laser fixed fixed to toa motor a motor and and a camera a camera with with an infrared an infrared ◦ (IR)(IR) filter,filter, as shown shown in in Figure Figure 2.2 The. The line line laser laser used used in our in system our system has 90 has° fan 90 anglesfan at angles 850 at 850nm nmwavelength wavelength (FLEXPOINT (FLEXPOINT MVnano, MVnano, Laser Components, Laser Components, Bedford, Bedford, NH, USA). NH, We USA). de- We designedsigned a mount a mount that that can can fix fixand and adjust adjust the theorientation orientation of the of theline linelaser. laser. ThisThis mount mount has has twotwo degreesdegrees ofof freedomfreedom rotating about pitch pitch and and roll roll axes.
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