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Sensors
Volume 25
Issue 20
10.3390/s25206455
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Binocular Stereo Vision-Based Structured Light Scanning System Calibration and Workpiece Surface Measurement Accuracy Analysis

by
Xinbo Zhang
1,
Li Luo
1,
Rui Ma
1,
Yuexue Wang
2,
Shi Xie
2,
Hao Zhang
2,
Yiqing Zou
2,
Xiaohao Wang
1 and
Xinghui Li
1,*
1
Tsinghua Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, China
2
Equipment Technology Research Institute, Liuzhou OVM Machinery Co., Ltd., Liuzhou 545006, China
*
Author to whom correspondence should be addressed.
Sensors 2025, 25(20), 6455; https://doi.org/10.3390/s25206455 (registering DOI)
Submission received: 21 September 2025 / Revised: 12 October 2025 / Accepted: 16 October 2025 / Published: 18 October 2025
(This article belongs to the Section Sensing and Imaging)
Versions Notes

Abstract

Precise online measurement of large structural components is urgently needed in modern manufacturing and intelligent construction, requiring a measurement range over 1 m, near-millimeter accuracy, second-level measurement speed, and adaptability to complex environments. In this paper, three mainstream measurement technologies, namely the image method, line laser scanning method, and structured light method, are comparatively analyzed. The structured light method exhibits remarkable comprehensive advantages in terms of accuracy and speed; however, it suffers from the issue of occlusion during contour measurement. To tackle this problem, multi-camera stitching is employed, wherein the accuracy of camera calibration plays a crucial role in determining the quality of point cloud stitching. Focusing on the cable tightening scenario of meter-diameter cables in cable-stayed bridges, this study develops a contour measurement system based on the collaboration of multiple structured light cameras. Measurement indicators are optimized through modeling analysis, system construction, and performance verification. During verification, four structured light scanners were adopted, and measurements were repeated 11 times for the test workpieces. Experimental results demonstrate that although the current measurement errors have not yet been stably controlled within the millimeter level, this research provides technical exploration and practical experience for high-precision measurement in the field of intelligent construction, thus laying a solid foundation for subsequent accuracy improvement.
Keywords: structured light; multi-camera calibration; large structural component measurement; measurement accuracy; point cloud stitching structured light; multi-camera calibration; large structural component measurement; measurement accuracy; point cloud stitching

Share and Cite

MDPI and ACS Style

Zhang, X.; Luo, L.; Ma, R.; Wang, Y.; Xie, S.; Zhang, H.; Zou, Y.; Wang, X.; Li, X. Binocular Stereo Vision-Based Structured Light Scanning System Calibration and Workpiece Surface Measurement Accuracy Analysis. Sensors 2025, 25, 6455. https://doi.org/10.3390/s25206455

AMA Style

Zhang X, Luo L, Ma R, Wang Y, Xie S, Zhang H, Zou Y, Wang X, Li X. Binocular Stereo Vision-Based Structured Light Scanning System Calibration and Workpiece Surface Measurement Accuracy Analysis. Sensors. 2025; 25(20):6455. https://doi.org/10.3390/s25206455

Chicago/Turabian Style

Zhang, Xinbo, Li Luo, Rui Ma, Yuexue Wang, Shi Xie, Hao Zhang, Yiqing Zou, Xiaohao Wang, and Xinghui Li. 2025. "Binocular Stereo Vision-Based Structured Light Scanning System Calibration and Workpiece Surface Measurement Accuracy Analysis" Sensors 25, no. 20: 6455. https://doi.org/10.3390/s25206455

APA Style

Zhang, X., Luo, L., Ma, R., Wang, Y., Xie, S., Zhang, H., Zou, Y., Wang, X., & Li, X. (2025). Binocular Stereo Vision-Based Structured Light Scanning System Calibration and Workpiece Surface Measurement Accuracy Analysis. Sensors, 25(20), 6455. https://doi.org/10.3390/s25206455

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