Development of a laser scanning projection system with a dual-diameter fitting method and particle swarm optimization

Area of Science:

• Industrial Manufacturing
• Optical Engineering
• Computer Vision

Background:

• Laser scanning projection is crucial for improving assembly efficiency in industrial manufacturing.
• Accurate calibration and projection are essential for effective laser scanning systems.
• Existing methods require refinement for precise coordinate transformation and target localization.

Purpose of the Study:

• To develop a precise mathematical model for laser scanning projection calibration.
• To enhance the accuracy of coordinate transformation using an optimized particle swarm optimization (PSO) algorithm.
• To validate the performance of a novel laser scanning projection system through experimental testing.

Main Methods:

• Developed a mathematical model for the calibration process.
• Proposed a dual-diameter fitting method for retroreflective target center extraction.
• Implemented a particle swarm optimization (PSO) algorithm for solving the world-to-projector coordinate transformation matrix.
• Designed and built a new laser scanning projection setup and a LabVIEW-based control system.

Main Results:

• Simulation experiments showed a maximum error of 1.82×10^-6 mm for retroreflective target positions.
• Experimental results yielded a maximum beam steering angle error of 5.215668×10^-9 degrees.
• The developed laser scanning projection system demonstrated a position error of less than 0.5 mm on a standard workpiece.

Conclusions:

• The proposed dual-diameter fitting and PSO optimization significantly improve calibration accuracy.
• The novel laser scanning projection system achieves high precision suitable for industrial applications.
• The system's performance validates its effectiveness in accurate component outline projection for manufacturing.