Automated extrinsic calibration of solid-state frame LiDAR sensors with non-overlapping field of view for monitoring indoor stockpile storage facilities

Abstract

Several industrial and commercial bulk material management applications rely on accurate, current stockpile volume estimation. Proximal imaging and LiDAR sensing modalities can be used to derive stockpile volume estimates in outdoor and indoor storage facilities. Among available imaging and LiDAR sensing modalities, the latter is more advantageous for indoor storage facilities due to its ability to capture scans under poor lighting conditions. Evaluating volumes from such sensing modalities requires the pose (i.e., position and orientation) parameters of the used sensors relative to a common reference frame. For outdoor facilities, a Global Navigation Satellite System (GNSS) combined with an Inertial Navigation System (INS) can be used to derive the sensors’ pose relative to a global reference frame. For indoor facilities, GNSS signal outages will not allow for such capability. Prior research has developed strategies for establishing the sensor position and orientation for stockpile volume estimation while relying on multi-beam spinning LiDAR units. These approaches are feasible due to the large range and Field of View (FOV) of such systems that can capture the internal surfaces of indoor storage facilities.

The mechanical movement of multi-beam spinning LiDAR units together with the harsh conditions within indoor facilities (e.g., excessive humidity, wide range of temperature variation, dust, and corrosive environment in deicing salt storage facilities) limit the use of such systems. With the increasing availability of solid-state LiDAR units, there is an interest in exploring their potential for stockpile volume estimation. Despite their higher robustness to harsh conditions, solid-state LiDAR units have shorter distance measurement range and limited FOV when compared with multi-beam spinning LiDAR. This research presents a strategy for the extrinsic calibration (i.e., estimating the relative pose parameters) of installed solid-state LiDAR units inside stockpile storage facilities. The extrinsic calibration is made possible using deployed spherical targets and a complete, reference scan of the facility from another LiDAR sensing modality. The proposed research introduces strategies for: 1) automated extraction of the spherical targets; 2) automated matching of these targets in the solid-state LiDAR and reference scans using invariant relationships among them; and 3) coarse-to-fine estimation of the calibration parameters. Experimental results in several facilities have shown the feasibility of using the proposed methodology to conduct the extrinsic calibration and volume evaluation with an error percentage less than 3.5% even with occlusion percentages reaching up to 50%.