Adaptive projection intensity adjustment for avoiding saturation in three-dimensional shape measurement

Phase-based fringe projection methods have been commonly used for three-dimensional (3D) measurements. However, image saturation results in incorrect intensities in captured fringe pattern images, leading to phase and measurement errors. Existing solutions are complex. This paper proposes an adaptive projection intensity adjustment method to avoid image saturation and maintain good fringe modulation in measuring objects with a high range of surface reflectivities. The adapted fringe patterns are created using only one prior step of fringe-pattern projection and image capture. First, a set of phase-shifted fringe patterns with maximum projection intensity value of 255 and a uniform gray level pattern are projected onto the surface of an object. The patterns are reflected from and deformed by the object surface and captured by a digital camera. The best projection intensities corresponding to each saturated-pixel clusters are determined by fitting a polynomial function to transform captured intensities to projected intensities. Subsequently, the adapted fringe patterns are constructed using the best projection intensities at projector pixel coordinate. Finally, the adapted fringe patterns are projected for phase recovery and 3D shape calculation. The experimental results demonstrate that the proposed method achieves high measurement accuracy even for objects with a high range of surface reflectivities.