Method for large-range structured light system calibration

Structured light system calibration often requires the usage of a calibration target with a similar size as the field of view (FOV), which brings challenges to a large-range structured light system calibration since fabricating large calibration targets is difficult and expensive. This paper presents a large-range system calibration method that does not need a large calibration target. The proposed method includes two stages: (1) accurately calibrate intrinsics (i.e., focal lengths and principle points) at a near range where both the camera and projector are out of focus, and (2) calibrate the extrinsic parameters (translation and rotation) from camera to projector with the assistance of a low-accuracy, large-range three-dimensional (3D) sensor (e.g., Microsoft Kinect). We have developed a large-scale 3D shape measurement system with a FOV of 1120 mm×1900 mm×1000 mm. Experiments demonstrate our system can achieve measurement accuracy as high as 0.07 mm with a standard deviation of 0.80 mm by measuring a 304.8 mm diameter sphere. As a comparison, Kinect V2 only achieved mean error of 0.80 mm with a standard deviation of 3.41 mm for the FOV of measurement.