To address the issue of phase jump errors caused by the misalignment between wrapped phase truncation positions and fringe order transition positions in Gray-code-assisted phase unwrapping technique, a large number of methods for avoiding such jump errors have been developed in recent years. This paper proposes a highly error-tolerant phase unwrapping method based on Gray-coded light for misalignment error scenarios. This method first calculates original fringe orders using traditional Gray-coded method, then performs a modulo operation on these orders, and leverages the characteristic that adjacent-value orders should be equal to derive two complementary sets of fringe orders. Subsequently, using obtained original fringe orders and the critical points where the wrapped phase transitions between positive and negative values, the wrapped phase is partitioned into a series of confidence regions. Finally, phase unwrapping is conducted for each confidence sub-region, yielding a continuous absolute phase free of jump errors. Through experiments on facial height reconstruction, phase retrieval under harsh scenario, phase retrieval covering different misalignment error scenarios, and phase retrieval of complex objects, it is verified that the proposed method can extend the maximum allowable misalignment error from the existing one-third of a wrapped phase cycle to half of a wrapped phase cycle, without increasing additional Gray-coded patterns. The proposed method enhances the tolerance of the phase unwrapping method to the misalignment error, improves phase retrieval accuracy, and does not increase computational time while ensuring high precision and robustness. Therefore, it is well-suited for high-precision optical online detection scenarios.
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