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Illumination system optimal design for geometry measurement of complex cutting tools in machine vision

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Abstract

Precision geometry measurement of complex cutting tools has a significant impact on the machinability of components in the industry. However, acquiring high-quality images in machine vision is a challenging problem due to the large slope and complex geometry. In view of the vital function of illumination, this paper proposed a method of optimal design for the LED array. First, the calculation model of irradiance distribution on the measurement plane is established, and the properties of the reflected light from the surface of cutting tools are analyzed based on the BRDF theory. Then, the optimal parameters are solved through the specific algorithm flow for the LED array design. Finally, a flexible LED light source is fabricated with the optimal parameters for different features of the cutting tools and used in the measurement. The measurement results show that the error of the optimized light source is less than 1%, and compared with the off-the-shelf light, the measurement accuracy is improved by 9.5% on average. Moreover, this method also presents the potential applied to other complex objects.

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Funding

This work was supported by the National Key Research and Development Project of China (Grant No. 2018YFA0703304), the National Natural Science Foundation of China (No. 52125504, 92148301), and the Natural Science Foundation of Liaoning Province of China (2020-BS-059).

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Linggong Road, Dalian, 116024, Liaoning, China

    Wenqi Wang, Wei Liu, Yang Zhang, Peidong Zhang, Likun Si & Mengde Zhou

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  1. Wenqi Wang
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  2. Wei Liu
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  3. Yang Zhang
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  4. Peidong Zhang
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  5. Likun Si
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Correspondence to Yang Zhang.

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Author contribution

Wenqi Wang: conceptualization, data curation, formal analysis, methodology, supervision, validation, writing — original draft, writing — review and editing. Wei Liu: project administration, supervision, validation, funding acquisition, investigation, writing — review and editing. Yang Zhang: funding acquisition, investigation, project administration, writing — review and editing. Peidong Zhang: data curation, formal analysis, visualization, software. Likun si: investigation, resources. Mengde Zhou: investigation, resources.

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Wang, W., Liu, W., Zhang, Y. et al. Illumination system optimal design for geometry measurement of complex cutting tools in machine vision. Int J Adv Manuf Technol 125, 105–114 (2023). https://doi.org/10.1007/s00170-022-10491-x

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  • DOI: https://doi.org/10.1007/s00170-022-10491-x

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