The rotational speed vectors of the bearing balls affect their service life and running performance. Observing the actual rotational speed of the ball is a prerequisite for revealing its true motion law and conducting sliding behavior simulation analysis. To address the need for accuracy and real-time measurement of spin angular velocity, which is also under high-frequency and high-speed ball motion conditions, a new measurement method of ball rotation vectors based on a binocular vision system is proposed. Firstly, marker points are laid on the balls, and their three-dimensional (3D) coordinates in the camera coordinate system are calculated in real time using the triangulation principle. Secondly, based on the 3D coordinates before and after the movement of the marker point and the trajectory of the ball, the mathematical model of the spin motion of the ball was established. Finally, based on the ball spin motion model, the three-dimensional vision measurement technology was first applied to the measurement of the bearing ball rotation vector through formula derivation, achieving the analysis of bearing ball rolling and sliding characteristics. Experimental results demonstrate that the visual measurement system with the frame rate of 100 FPS (frames per second) yields a measurement error within ±0.2% over a speed range from 5 to 50 RPM (revolutions per minute), and the maximum measurement errors of spin angular velocity and linear velocity are 0.25 °/s and 0.028 mm/s, respectively. The experimental results show that this method has good accuracy and stability in measuring the rotation vector of the ball, providing a reference for bearing balls’ rotational speed monitoring and the analysis of the sliding behavior of bearing balls.

Binocular structured light systems are widely used in 3D measurements. In the condition of complex and local highly reflective scenes, to obtain more 3D information, binocular systems are usually divided into two pairs of devices, each having a Single Camera and a Projector (SCP). In this case, the binocular system can be seen as Dual Cameras-Projector (DCP) system. In the DCP calibration, the Left-SCP and Right-SCP need to be calibrated separately, which leads to inconsistent parameters for the same projector, thus reducing the measurement accuracy. To solve this problem and improve manoeuvrability, a coupled calibration method using an orthogonal phase target is proposed. The 3D coordinates on a phase target are uniquely determined by the binocular camera in DCP, rather than being calculated separately in each SCP. This ensures the consistency of the projector parameters. The coordinates of the projector image plane are calculated through the unwrapped phase, while the parameters are calibrated by the plane calibration method. In order to extract sub-pixel accuracy feature points, a method based on polynomial fitting using an orthogonal phase target is exploited. The experimental results show that the reprojection error of our method is less than 0.033 pixels, which improves the calibration accuracy.