A Novel Dynamic Light-Section 3D Reconstruction Method for Wide-Range Sensing

Existing galvanometer-based laser-scanning systems are challenging to apply in multi-scale 3D reconstruction because of the difficulty in achieving a balance between a high reconstruction accuracy and a wide reconstruction range. This paper presents a novel method that synchronizes laser scanning by switching the field-of-view (FOV) of a camera using multi-galvanometers. Beyond the advanced hardware setup, we establish a comprehensive geometric model of the system by modeling dynamic camera, dynamic laser, and their combined interaction. Furthermore, since existing calibration methods mainly focus on either dynamic lasers or dynamic cameras and have certain limitations, we propose a novel high-precision and flexible calibration method by constructing an error model and minimizing the objective function. The performance of the proposed method was evaluated by scanning standard components. The results show that the proposed 3D reconstruction system achieves an accuracy of 0.3 mm when the measurement range is extended to 1100 mm × 1300 mm × 650 mm. This demonstrates that for meter-scale reconstruction ranges, a sub-millimeter measurement accuracy is achieved, indicating that the proposed method realizes multi-scale 3D reconstruction and simultaneously allows for high-precision and wide-range 3D reconstruction in industrial applications.