Enhanced Calibration of a Laser Profiler Sensor for 3D Inspection and Reconstruction

In recent decades, inspection and three-dimensional reconstruction of gas and water pipes have required high-precision sensors capable of operating in confined and low-texture environments, which presents challenges to traditional sensing technologies. This paper presents the design of both hardware and software for a laser profiler sensor, introducing a novel approach to calibrating the sensor to enhance its accuracy and functionality in industrial inspections. We introduce a new calibration method suitable for both conic and planar lasers, with calibration achieved through a two-step process: initial multiposition binocular-structured light calibration and subsequent refinement using a standard ring gauge. The calibration method is uniquely designed to be compatible with both cone- and plane-type calibrations, providing a robust and versatile solution for industrial laser profiling. We demonstrate the efficacy and accuracy of our proposed calibration method, with errors consistently remaining below 1 mm, thus validating the reliability of the reconstruction process.