We present a novel multifunctional binocular stereovision sensor for various three-dimensional (3D) inspection tasks. It not only avoids the socalled correspondence problem of passive stereo vision, but also possesses the uniform mathematical model. We also propose a novel approach to estimating all the sensor parameters with free-position planar reference object. In this technique, the planar pattern can be moved freely by hand. All the camera intrinsic and extrinsic parameters with coefficient of lens radial and tangential distortion are estimated, and sensor parameters are calibrated based on the 3D measurement model and optimized with the feature point constraint algorithm using the same views in the camera calibration stage. The proposed approach greatly reduces the cost of the calibration equipment, and it is flexible and practical for the vision measurement. It shows that this method has high precision by experiment, and the sensor measured relative error of space length excels 0.3%.
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