Robust Localization of Flange Interface for LNG Tanker Loading and Unloading Under Variable Illumination a Fusion Approach of Monocular Vision and LiDAR

The automated localization of the flange interface in LNG tanker loading and unloading imposes stringent requirements for accuracy and illumination robustness. Traditional monocular vision methods are prone to localization failure under extreme illumination conditions, such as intense glare or low light, while LiDAR, despite being unaffected by illumination, suffers from limitations like a lack of texture information. This paper proposes an illumination-robust localization method for LNG tanker flange interfaces by fusing monocular vision and LiDAR, with three scenario-specific innovations beyond generic multi-sensor fusion frameworks. First, an illumination-adaptive fusion framework is designed to dynamically adjust detection parameters via grayscale mean evaluation, addressing extreme illumination (e.g., glare, low light with water film). Second, a multi-constraint flange detection strategy is developed by integrating physical dimension constraints, K-means clustering, and weighted fitting to eliminate background interference and distinguish dual flanges. Third, a customized fusion pipeline (ROI extraction-plane fitting-3D circle center solving) is established to compensate for monocular depth errors and sparse LiDAR point cloud limitations using flange radius prior. High-precision localization is achieved via four key steps: multi-modal data preprocessing, LiDAR-camera spatial projection, fusion-based flange circle detection, and 3D circle center fitting. While basic techniques such as LiDAR-camera spatiotemporal synchronization and K-means clustering are adapted from prior works, their integration with flange-specific constraints and illumination-adaptive design forms the core novelty of this study. Comparative experiments between the proposed fusion method and the monocular vision-only localization method are conducted under four typical illumination scenarios: uniform illumination, local strong illumination, uniform low illumination, and low illumination with water film. The experimental results based on 20 samples per illumination scenario (80 valid data sets in total) show that, compared with the monocular vision method, the proposed fusion method reduces the Mean Absolute Error (MAE) of localization accuracy by 33.08%, 30.57%, and 75.91% in the X, Y, and Z dimensions, respectively, with the overall 3D MAE reduced by 61.69%. Meanwhile, the Root Mean Square Error (RMSE) in the X, Y, and Z dimensions is decreased by 33.65%, 32.71%, and 79.88%, respectively, and the overall 3D RMSE is reduced by 64.79%. The expanded sample size verifies the statistical reliability of the proposed method, which exhibits significantly superior robustness to extreme illumination conditions.