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Real-Time 3D Shape Measurement With Digital Stripe Projection by Texas Instruments Micro Mirror Devices DMD
Real-Time 3D Shape Measurement With Digital Stripe Projection by Texas Instruments Micro Mirror Devices DMD
ABSTRACT
The fast, contact-free and highly precise shape measurement of technical objects is of key importance
in the scientific-technological area as well as the area of practical measurement technology. The appli-
cation areas of contact-free surface measurement extend across widely different areas, e.g., the auto-
mation of production processes, the measurement and inspection of components in microsystem tech-
nology or the fast 3D in-vivo measurement of human skin surfaces in cosmetics and medical technol-
ogy. This paper describes methodological and technological possibilities as well as measurement tech-
nology applications for fast optical 3D shape measurements using micromirror-based high-velocity
stripe projection. Depending on the available projector and camera facilities, it will be possible to shoot
and evaluate complete 3D surface profiles within only a few milliseconds.
1. INTRODUCTION
After great reservations from industry against optical measurement techniques, which were founded on
failures and unfulfilled expectations in the 70s and 80s, these measurement techniques are currently
regaining increasing interest in industry. This is caused by increased requirements for the assessment of
3D component geometry in research and development and above all in quality assurance. Conventional
mechanical sensoring devices can fulfill the upcoming measurement tasks only partially or not at all.
Moreover, developments in microcomputer technology, digital signal processing and optoelectronics
offer completely new possibilities for the design and performance capabilities of optical measurement
systems, which could not be thought of in the past. Among these many possibilities is the use of pixel-
wise controllable digital light projectors on the basis of micromirrors for measurement technology.
In Three-Dimensional Image Capture and Applications Ill, Brian D. Corner, Joseph H. Nurre,
90 Editors, Proceedings of SPIE Vol. 3958 (2000) • 0277-786X/00/$1 5.00
The basic principle of the optical 3D measurement technique used is the stripe projection. Stripe pro-
jection techniques have already been used for many years in the optical 3D measurement technology,
for widely differing measurement tasks in research and industry. Applications extend to the micro- as
well as the macro-area. For the generation of stripe patterns, various methods are used. In early years,
solid grids were used as projection systems, produced by photographic or photolithographic means.
Due to extensive developments in the area of multimedia projectors, pixel-wise addressable projection
systems on the basis of micromirror projectors [1 , 2] are currently increasingly used. Micromirror pro-
jectors in optical 3D measurement technology offer the special advantage of generating freely
choosable digital light pat-tems in the form of stripes, markings or ring structures [3, 4, 5].
CCDcamera CCD-camera
sensor
U,
projection optics
Analogous to the known triangulation processes, which are based on the projection of a single light
spot or light section, the stripe projection is an area triangulation process. Thus, with this method, the
3D scanning of the component geometry can be achieved without movement of the optical sensor or
the measured object.
91
D: projection area
measuring object
For practical measurement facilities, in most cases, a stripe projection array according to fig. ic or fig.
2 will be chosen, where the camera axis (observation direction) is positioned vertically to the plane of
the measured object. In this way, the influence of perspective distortions of the object shape by the
camera lens can best be kept under control.
According to equation ( 1 ), the height information to be measured is included in the phase term A(x,y)
and can be determined by solving the linear equation ( 1). In practical surface measurements, equation
(1) will usually be solved experimentally, by application of the so-called phase-shift technique { 6].
The basic idea of the phase-shift technique is the step-wise shifting of an equidistant stripe pattern by a
constant phase angle (x,y) within a 3600 period and the taking of single images by CCD camera.
92
In the evaluation result of the linear equation system ( 2 ), the A(x,y) phase, and thus the interesting
profile height in the x-y plane, is determined by an arctan function:
To avoid erroneous results from the stripe evaluations, it is necessary that the measured object is abso-
lutely at rest during the image taking of the respective phase-shifted stripe patterns. Particularly when
practical measurements are conducted directly at production sites or on complicated surfaces like hu-
man skin, there is a danger that erroneous position changes of the measured object can occur between
the respective image takings, which will naturally limit the measurement possibilities and also the
measurement accuracies considerably.
To avoid error influences resulting from external disturbances during stripe projection, the possibility
of a high-velocity stripe projection was created which uses digital micromirror projectors and makes it
possible to scan and evaluate a complete 3D surface profile within only a few milliseconds.
93
0
minor is tilted at an angle of± 100, controlled by
a computer. The movement between "ON" and
"OFF" takes less than 20 is. In "ON" position,
OFF /1
the light is then projected via the projection op-
// tics directly onto the measurement point of the
/
object to be measured, while in "OFF" position
//
/ the light is projected onto an absorber. In this
way, all micromirrors can be moved exactly by
1O computer control and make the generation of a
grey-scaled projection image within a video
frame possible.
l6pm
Fig. 4 Function principle of a DMD
In case one or more corresponding micromirrors are in ON position during a video frame, a sequence
of binary images with a maximum intensity (8 bit grey scale: 255) is produced. E.g., if the grey value of
128 is to be produced, the respective micromirrors exposed to this grey value by the computer are kept
in OFF position for one half of the video frame and in ON position for the other half. For the projection
of other grey values, the process is analogous.
94
For application in stripe projection technology, micromirror projectors offer the possibility, by exact
intensity control, to generate exact sinus-shaped intensity distributions of the projected stripe patterns.
Non-linearities in the intensity curves of the projected stripe patterns are, as a rule, responsible for sys-
tematic errors in the measurement result. An analysis of the stripe-pattern intensities theoretically cal-
culated and generated by micromirror projection yields the two intensity curves shown in fig. 5 below.
95
Fig. 5 Comparison between the theoretically calculated and the CCD-camera-taken digital
sinus-shaped stripe patterns
The use of proj ectors in optical measurement technology requires, in addition to a disturbance-free
projection of the generated images (stripe patterns), that these are taken by a CCD matrix camera and
can be fed into a measurement and evaluation computer for further processing in the sense of 3D meas-
urement technology. In this way, a closed control circuit between measurement and control computer,
measured object and CCD shooting camera is created, as depicted in fig. 6.
96
A lot of practical applications of the digital stripe projection within the industrial 3D measuring tech-
nique needs fast velocity for the recording and evaluation of the measurement data. This is very im-
portant, for instance, in the integrated manufacturing inspection in the automotive industry such as the
fast optical 3D invivo measurement of skin in cosmetics industry or medical applications, respectively.
The lasing rate in the optical 3D measuring technique based on digital stripe projection by digital mi-
cromirror devices is determined essentially by
. the refresh frequency of the used CCD-camera
. the pattern build-up time ofthe digital micromirror device
. the data transfer from the CCD-camera to the host computer.
In the optical 3D metrology are normally used CCD-cameras with a refresh frequency of 30 or 60 Hz,
what is very important in connection with the use ofthe digital micromirror projector.
The complete image build-up frequency of the digital micromirror projector to the projection of colour
pictures is 60 Hz or 33,3 ms. In this time is projected the coloured picture consisting of the three pri-
mary colours and produced by a colour multiplexing. In case of the one-chip DMD, most interesting for
optical 3D measurements, colour multiplexing is carried-out by a colour wheel rotating in the optical
path of the DLP-projector. In the process of a DLP clock pulse of 33,3 ms three primary colours will be
splitted in for parts of the DLP clock pulse of each length 2,8 ms or 360 Hz. In this way are projected
light intensities between 0 and 255 bits analogous an ON/OFF-switch. The diagram in the following
fig. 7 shows exemplary the separation of the DLP clock pulse in the twelve individual periods of col-
ours.
R
2,8 ms
33 3 ms
Fig. 7 Separation of the DLP clock pulse in twelve individual colour periods
Because the stripe projection is based on interferometric concepts only grey-scales of the light intensity
is from interest and no colour information. In this way can be refused on the use of a colour wheel in
the path of the digital projection system. In case of the stripe projection to the measuring of 3D shapes
are always used the recording of single picture sequencies consisting of stripes with different width
(grey-code technique) and/or stripe patterns highly precisely shifted by a small amount (phase-shift
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The stripe pattern in the following fig. 9 shows the finishing of the picture build-up of the DMD pro-
jector.
Fig. 9 1 welve single pictures 01 a DMD clock pulse showing a finished picture build-up
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3. MEASUREMENT RESULTS
The applications of digital stripe projection in micromeasurement technology presented here extend to
optical 3D scanning of microprofiles and optical roughness inspection.
In both cases, the MikroCAD optical 3D measurement system is used, whose 1 -axis and 3-axis ver-
sions are shown in fig. 10. According to the required vertical and lateral resolutions, suitably adapted
projection and shooting optics and CCD matrix cameras are used.
measuring neau witn i axis unit measuring head with 3 axis unit
Fig. 10 Versions of the MicroCAD optical measuring system
The CCD camera with telecentric shooting optics can be directly integrated in the optical measuring
head or mounted on the side of the measuring head case. integration of the CCD camera with shooting
optics in the optical measuring head is advantageous in cases where the user is not supposed to make
changes in the measurement field. Mounting the shooting optics with camera outside the measuring
head offers the user the possibility to replace the shooting optics as well as the CCD camera according
to his own needs. The optical measuring head itself is designed according to the laws of stripe projec-
tion, as can be seen from the principle drawing in fig. 11, and consists of the following three main
components:
• DMD (Digital Micromirror Device)
• TI mainboard
• projection and shooting optics
99
Taking some typical application examples, the measurement possibilities of the N'likroCAD optical
measuring system for the scanning and evaluation of microstructures will be demonstrated.
CCE)-camra
collimation optics
- --
DLP-main board
DMD
projections-
lens
Mcasuring area
Fig. 11 Optical diagram of the MIcroCAD measuring head
In fig. 12, the scanning of the 3D profile of microcontacts on a chip is demonstrated. The goal of this
measurement technology application from the area of microelectronics was the provision of a 3D
measurement facility for the fast geometrical surveying of microcontacts in a near-production environ-
ment.
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In the production of reading heads for computer hard disks, the exact execution of the respective read-
ing tracks constitutes an essential criterion for the quality of the reading head and thus for the function-
ality of the whole hard disk drive. Usually, the assessment of such reading tracks is undertaken with the
use of raster electron microscopes, which are located in a special measurement laboratory of the manu-
facturer. For this purpose, some reading heads are singled out in the framework of series control or in
100
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grey-scaled height picture 3D-Model
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As becomes clear from the two application examples from the areas of microelectronics and microsys-
tern technology, the use of the digital stripe projection technique on the basis of micrornirrors is very
manifold. But the application of this micro-optical 3D measurement method is not limited by far only
to the area of microtechnology. Due to the very simple technical handling as well as the favorable cost
requirements, its application possibilities extend to very different technical areas, as will be clarified by
the following three application examples from the measurement of criminological objects, the incas-
urement of structured metal sheet surfaces from automobile manufacturing and the measurement of
bank notes. Criminology is, among other things, faced with the task of fast reading the scratch traces of
burglary tools, e.g., in order to draw conclusions whether such a tool was used for different criminal
101
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3D- model 2D-profile intersection
The fast 3D scanning of surface roughness is evolving into a fundamental requirement in industry and
particularly for the assessment of functional surfaces in automobile construction. Functional surfaces
determine the functional behavior, on the one hand in the production process and on the other hand in
the actual operational state of the component.
E.g., this applies, to a very large degree, to the production of vehicle body parts. The metal sheets used
there must, on the one hand, continue to become thinner, due to extreme light-weight construction. On
the other hand, they must be suitable for high-velocity deformation in metal-sheet transfer lines and
optimal subsequent application of paint. With the goal of fulfilling these requirements, the steel indus-
try produces sheets that are furnished with a micro-structure in the production process which more and
more conforms to said requirements. Such microstructures can be created by surface treatment with
102
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.22 •tC 22 2 24 34
The measurement graphs in fig. 15 show the typical surface structure of an automobile metal sheet
which was surface-structured by an EBT process and is marked by small crater-shaped profiles. These
crater-shaped profiles, which are microscopically small and only a few micrometers deep, provide for
good shaping properties of the sheet during the high-velocity deformation, by advantageous distribution
of greasing agents, and at the same time for a structure well suited for subsequent painting. The fol-
lowing fig. 15 shows a 2D-profile intersection and geometric measurements of the microstructure of a
EBT-treated sheet metal taken from the 3D plot in fig. 15.
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0 800
0.400
-0 39
-Q ?9
-I 20
-t 60
103
Fig. 17 Result of determining the area roughness parameters on an EBT-treated metal sheet
by digital stripe projection based on micromirrors
104
Starting with measurement technology and methodology fundamentals of the digital stripe
projection with micromirrors, application possibilities of this measurement method in the op-
tical 3D measurement technology were described. Special application possibilities and advan-
tages ofthis method for conventional measurement technology as well as specifically new ap-
plications in the micro- and automobile measurement technology were presented by the use of
practical measurement examples.
REFERENCES
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2. Hombeck, L. J. : Digital Light ProcessingTM and MEMS: Timely Convergence for Bright
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ofFringe '97; 3rd Int. Workshop on "Automatic Processing ofFringe Patterns"; Bremen,
September 15 - 17, 1997
5. Frankowski, G., Reil3ner, H.. Rapid 3D Surface Shape Measuring Using Digital Fringe
Projection by Micromirror Devices, Internationales Oberflachenkoioquim 2000, Chem-
nitz, Feb 1 - 3, 2000
6. Monk, D. W. and Gale, R.: The Digital Micromirror Device for Projection Display (invi-
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105