Cannot get repeatable stereo calibration

Hello all. I am struggling to get a repeatable stereo caibration. Hopefully someone can give me some pointers. A little bit about my setup:
I have a pair of AVT Manta GigE cameras (1292 x 964) paired with Tamron 23FM25SP lenses. The cameras are mounted on a rigid (12mm thick) aluminium plate and are currently set to be around 895mm apart.The cameras are toed in slightly so that the centres of the images intersect around 4 metres from the cameras. The cameras are securely mounted via adapter plates and bolts. They cannot move.
I have a calibration grid along the lines of the NI example grid. Mine is 28X20 black dots spaced around 13mm apart (centre to cente) with each dot being around 5mm diameter. I am aware of the NI guidelines on suitable calibration grids, and mine seems to be well within the recommended bounds. The grid was formed by laser printing onto A3 paper and then using spray adhesive to fis to a rigid carbon fibre panel. It is flat and doesn't deform when in use.
So, here is my problem: when I use the calibration grid to calibrate the cameras I sometimes get a good calibration and sometimes not. When I get a good calibration and attempt to repeat exactly the same process I get a different result. What do I mean by a good calibration? When I go on to use the stereo calibration in my system which tracks a circular feature in 3D space I get good accurate measurements (well sub-mm in the cross camera axes and ~1mm depth resolution, over a ange of 600mm in each axis centred around 3000mm from the cameras. The centres of the circular features in each image lie on the same horizontal image line as expected in the rectified images for a well calibrated camera pair. When I get this 'good' calibration the distance between the cameras as returned by the 'IMAQ get binocular stereo calibration info 2' VI (the magniture of the translation vector) is around the correct distance of 895mm. However, when I perform the calibration lots of times I get quite a spread of camera separations (up to 20mm either side of correct). When I get a significant error in the camera separation the accuracy of the system degrades dramatically and the centres of the circular feature line on progressively further apart horizontal lines (there's one distance from the camera when they're on the same line, and they move apart either side of that distance).
I have gathered a set of 10 images of the calibration target and set up a VI to use a subset of the images for the calibration process and iterate through permutations to investigate the repeatabilty. I get a similar spread of results for inter-camera distance.
Does anyone have a feel for whether what I'm trying to do is sensible / achievable? Any tips for repeatable calibration? For instance, should the calibration grid be at a constant distance from the cameras when it is presented at the different anglres, or should a range of distances be used? If it should be the same distance, how accurately should this distnace be maintained?
Thanks, Chris
Regards,
Chris Vann
Certified LabVIEW Developer

Hi Christophe. Thanks for taking an interest. I am pretty sure that structured light is not relevant to the calibration stage being discussed here. Structured light is a useful technique for introducing detail to otherwise bland areas of an image to provide feature matching algorithms something to match against, but I don't see how it's relevant to calibrating against a grid of dots. Happy if someone can correct me of course...
I have been using the NI example "Stereo Vision Example.vi" located in C:\Program Files (x86)\National Instruments\LabVIEW 2012\examples\Vision\3. Applications, and have also created my own system based upon that example. I get the same poor results with both. The path and file you suggested is not present on my machine (I'm running LV2012). Is the example you suggested the same? Maybe I should be trying it. Any ideas where I can get hold of it?
I have been using the techniques you suggest of presenting the calibration grid at a variety of angles and ensuring good coverage of the fields of view. I have spent upwards of 20 hours experimenting with different techniques and approaches, and cannot get repeatable results. But with the Matlab-based approach from Caltech using the same techniques I get good results. I am becoming increasingly confident there is an issue in the LV implementation.
Thanks,
Chris
Regards,
Chris Vann
Certified LabVIEW Developer

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