A non-coplanar high-precision calibration method for cameras based on an affine coordinate correction model

Traditional non-coplanar calibration methods such as Tsai's method have many problems, such as insufficient calibration accuracy, inconvenient operation, inaccurate models, etc. This paper proposes a new high-precision non-coplanar calibration method that aims to solve these problems. Like Tsai's method, the proposed calibration method utilizes a one-dimensional displacement stage and a two-dimensional plane target to generate a virtual 3D feature point sequence. As an improvement, an affine coordinate correction model is applied to ensure the accuracy and orthogonality of the obtained virtual 3D coordinates. A novel and accurate camera calibration model is further established. Compared with Tsai's model, which uses a radial alignment constraint and ignores the orthonormal constraint of the rotation matrix, the proposed calibration model fully considers the degrees of freedom of the camera's parameters to be calibrated, as well as the lens's nonlinear distortion parameters. More accurate analytical solutions of intrinsic and extrinsic parameters can be obtained with the proposed calibration model. Finally, a novel high-precision non-coplanar calibration method is proposed based on the proposed calibration model. The reprojection experiment proves that the calibration accuracy of this calibration method is better than that of Tsai's and Zhang's calibration methods under the same calibration conditions. As a supplement, a novel binocular camera system extrinsic parameter calibration method with known intrinsic parameters is proposed. With accurate intrinsic and extrinsic parameters, the binocular camera system's relative measurement accuracy could be within 1/10 000. Overall, this method can be used in experimental and industrial applications that require high-precision calibration parameters.