System and method for aligning a sensor assembly

Abstract

The present disclosure provides "a system and method for aligning a sensor assembly". The present disclosure relates to a system and method for aligning a sensor assembly for a vehicle. The sensor assembly is arranged along a vehicle body and has a sensing surface, and a measurement signal is emitted from the sensing surface. The sensor alignment system includes: an alignment gauge, which measures a reference angle of the sensor assembly; a sensor adjustment tool, which adjusts the position of the sensor assembly relative to the vehicle body; and a controller, which communicates with the alignment gauge and the sensor adjustment tool. The controller further operates the sensor adjustment tool to control the reference angle of the sensor assembly within a tolerance range.

Description

Technical Field

[0001] The present disclosure relates to a method for aligning a sensor assembly for a vehicle. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Many driver assistance features of new vehicles use forward-looking sensor assemblies, such as radar, to detect the environment around the vehicle. For example, radar assemblies detect other vehicles and obstacles on the road. To monitor the road ahead of the vehicle, such radar assemblies are generally aimed vertically within a preset range.

[0004] Some sensor assemblies are adjusted after vehicle assembly, for example at a workstation used for other vehicle inspections such as suspension alignment, and are adjusted manually by an operator. The time allocated for aligning the suspension may not be sufficient for aligning the sensor assembly, and thus may increase operating time and therefore cost. Furthermore, adding an additional offline workstation dedicated to sensor assembly alignment not only results in separate offline time being allocated for such adjustments, but also requires additional space and investment. The present disclosure addresses these and other issues associated with aligning a sensor assembly to a vehicle. Summary of the invention

[0005] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0006] In one form of the present disclosure, a sensor alignment system for aligning a sensor assembly is provided. The sensor assembly is disposed along a vehicle body and has a sensing surface from which a measurement signal is emitted. The sensor alignment system includes an alignment gauge operable to measure a reference angle of the sensor assembly, and the alignment gauge has a reference surface that contacts the sensing surface of the sensor assembly to measure the reference angle. The system includes: a sensor adjustment tool operable to adjust a position of the sensor assembly relative to the vehicle body; and a controller communicatively coupled to the alignment gauge and the sensor adjustment tool. The controller is configured to operate the sensor adjustment tool to control the reference angle of the sensor assembly within a tolerance range based on the reference angle measured by the alignment gauge and offset information, the offset information including one or more identified offsets that affect the angular position of the sensor assembly.

[0007] In another form, the sensor assembly is a radar assembly and the alignment gauge includes a clamp operable to attach to the radar assembly while the radar assembly measures the reference angle.

[0008] In one form, the offset information includes at least one of environmental offset, statistical offset, and sensor assembly offset.

[0009] In yet another form, the offset information includes environmental offsets including offsets associated with at least one of the sensor adjustment tool, the alignment gauge, and a platform on which the vehicle body is supported.

[0010] In one form, the offset information includes statistical offsets based on performance data of a plurality of sensor assemblies.

[0011] In another form, the offset information includes sensor assembly offset based on manufacturing offsets associated with the sensor assembly.

[0012] In yet another form, the controller is communicatively coupled to the alignment gauge via wireless communication.

[0013] In one form of the present disclosure, a method for aligning a sensor assembly disposed along a vehicle body is provided. The method includes: measuring a reference angle of the sensor assembly by an alignment gauge. The alignment gauge has a reference surface and is attached to the sensor assembly so that the reference surface is in contact with a sensing surface of the sensor assembly, and a measurement signal from the sensor assembly is emitted from the sensing surface. The method also includes: calculating a calibrated reference angle by a controller based on the measured reference angle and offset information, and adjusting the position of the sensor assembly using a sensor adjustment tool operable by the controller in response to the calibrated reference angle being outside an angular threshold range. The offset information is stored by the controller and includes one or more identified offsets that affect the angular position of the sensor assembly.

[0014] In another form, the method includes transmitting, by the alignment gauge, the measured reference angle to the controller via wireless communication.

[0015] In yet another form, adjusting the position of the sensor assembly further includes: transmitting a control signal to the sensor adjustment tool via the controller so that the sensor adjustment tool adjusts the position of the sensor assembly based on the calibrated reference angle and the angle threshold range; and driving a fastener via the sensor adjustment tool in response to receiving the control signal, wherein the fastener attaches the sensor assembly to the vehicle body.

[0016] In one form, the method includes: comparing, by the controller, the calibrated reference angle with the angular threshold range. The method also includes: in response to the calibrated reference angle being greater than an upper limit of the angular threshold range, driving the fastener in a first direction by the sensor adjustment tool; and in response to the calibrated reference angle being less than a lower limit of the angular threshold range, driving the fastener in a second direction different from the first direction by the sensor adjustment tool.

[0017] In another form the sensor assembly is a radar assembly.

[0018] In yet another form, the offset information includes at least one of environmental offset, statistical offset, and sensor assembly offset.

[0019] In yet another form, the offset information includes environmental offsets including offsets associated with at least one of the sensor adjustment tool, the alignment gauge, and a platform on which the vehicle body is supported.

[0020] In one form, the offset comprises a statistical offset based on performance data of a plurality of sensor assemblies.

[0021] In another form, the offset information includes sensor assembly offset based on manufacturing offsets associated with the sensor assembly.

[0022] In one form of the present disclosure, a method for aligning a vehicle radar assembly is provided. The method includes: measuring a reference angle of the radar assembly by an alignment gauge; transmitting the reference angle to a controller by the alignment gauge; and adjusting the position of the radar assembly based on the measured reference angle and offset information using a sensor adjustment tool operable by the controller, so that the reference angle is within an angle threshold range.

[0023] In another form, the offset information includes at least one of environmental offset, statistical offset, and sensor assembly offset.

[0024] In yet another form, the offset information is stored by the controller and includes one or more identified offsets that affect the angular position of the sensor assembly.

[0025] In another form, the method includes calculating, by the controller, a calibrated reference angle based on the measured reference angle and the offset information before adjusting the position of the radar assembly, and determining, by the controller, whether the calibrated reference angle is within the angle threshold range.

[0026] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order that the present disclosure may be better understood, various forms of the present disclosure given by way of example will now be described with reference to the accompanying drawings, in which:

[0028] Figure 1 is a side view illustrating a system for aligning a sensor assembly in accordance with the teachings of the present disclosure.

[0029] Figure 2 is a perspective view of a sensor assembly according to the teachings of the present disclosure, wherein an alignment gauge of the system is interfaced with the sensor assembly;

[0030] Figure 3 yes Figure 2 A perspective view of the alignment gauge; and

[0031] Figure 4 is a flow chart illustrating a method of aligning a sensor assembly according to principles of the present disclosure.

[0032] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0033] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0034] The present disclosure relates to a sensor alignment system that aligns a sensor assembly (such as a radar assembly) disposed along a body of a vehicle. As further described herein, in one form, the system includes: an alignment gauge for measuring a reference angle of the sensor assembly; a controller for determining whether the reference angle is within a set tolerance range; and a sensor adjustment tool operable by the controller for adjusting the position of the sensor assembly when the measured reference angle is outside the set range.

[0035] Hereinafter, the sensor assembly is provided as a radar assembly arranged along the bumper of the vehicle. It should be readily understood that the sensor assembly may be other suitable sensors and should not be limited to a radar assembly, and the sensor assembly may be arranged at other locations of the vehicle.

[0036] refer to Figure 1, a sensor alignment system 100 for aligning a radar assembly 108 according to the present disclosure is provided. Here, the radar assembly 108 is arranged along the bumper 106 of the vehicle body 102, and includes a radar antenna (not shown) and a housing 200 ( Figure 2 ) components. In operation, the radar assembly 108 is configured to detect the presence of a radar sensor 202 ( Figure 2 ) transmits radio waves and receives reflected radio waves, and the reflected radio waves are used to detect objects.

[0037] The sensor alignment system 100 includes an alignment gauge 112, a sensor adjustment tool 110, and a controller 114. In one form, the controller 114 is communicatively coupled to the alignment gauge 112 and the sensor adjustment tool 110 via wired or wireless communications (eg, Wi-Fi, Bluetooth, etc.).

[0038] The alignment gauge 112 is a measuring instrument, such as an inclinometer, that measures the inclination or, in other words, measures a reference angle 116 of the radar assembly 108 relative to the ground plane. The alignment gauge 112 transmits the reference angle 116 to the controller 114. Figure 2 and Figure 3 In one form, the alignment gauge 112 includes a fixture 206 configured to be attached to the radar assembly 108 and a reference surface 302 that interfaces with the sensing face 202 of the radar assembly 108. The alignment gauge 112 also includes a user interface, such as one or more buttons 304A and a display screen 304B, which can be operated by an operator to position the alignment gauge 112 on the radar assembly 108. The display screen 304B can display a message including the measured reference angle. Although the reference angle 116 is described as the angle between the reference surface 302 and the ground plane / platform 104, the angle can be defined in other suitable ways based on the position of the sensor assembly and the orientation of the sensing face 202. In addition, the alignment gauge shown in the drawings is only an example of a measuring tool for measuring the inclination of the radar assembly. Other suitable alignment gauges are also within the scope of the present disclosure.

[0039] The sensor adjustment tool 110 adjusts the position of the radar assembly 108 based on a control signal from the controller 114. In one form, the sensor adjustment tool 110 is a power tool configured to engage with a fastener 204 of the sensor assembly 108. In order to change the reference angle of the sensor assembly 108, the sensor adjustment tool 110 drives the fastener 204 in, for example, a first direction to increase the reference angle 116, and drives the fastener 204 in a second direction opposite to the first direction to decrease the reference angle. For example, in one form, the fastener 204 is a bolt, and the sensor adjustment tool 110 is a nut driver that is operable to drive (i.e., rotate) a nut in a clockwise direction to decrease the reference angle, and drive (i.e., rotate) the nut in a counterclockwise direction to increase the reference angle.

[0040] The controller 114 may be a computer including, for example, a processor, a computer readable medium, and other electronic components. The controller 114 may be located locally or remotely from the system 100 and may be controlled by an operator through a user interface, such as a keyboard 118 and a display 120 ( Figure 1 In one form, the controller 114 is configured to align the radar assembly 108 based on the measured reference angle and offset information.

[0041] The offset information includes one or more identified offsets that affect the angular position of the radar / sensor assembly 108. For example, the offset may include, but is not limited to, environmental offset, statistical offset, and sensor assembly offset. Environmental offset includes offsets associated with the manufacturing environment of the vehicle. For example, environmental offset includes the inclination of the platform 104 on which the vehicle is located and the tolerances associated with the sensor adjustment tool 110 and the alignment gauge 112, which may affect the measurement accuracy and adjustment of the sensor assembly. The statistical offset is based on data of previous sensor assemblies aligned by the system 100. For example, a database (not shown) may store data such as the part number of the sensor assembly, the make and model of the vehicle on which the sensor assembly is installed, and vehicle inspection test data indicating the performance of the sensor assembly when the sensor assembly is installed in the vehicle. Using the stored data, a statistical analysis is performed to determine, for example, alignment changes based on the make and model of the vehicle. The sensor assembly offset is a change or offset of the sensor assembly. For example, for a radar assembly, the offset is associated with a deviation associated with the position of the antenna in the housing 200. In one form, the sensor assembly offset is provided by the manufacturer of the sensor assembly.

[0042] The controller 114 stores the offset information in a memory. Although specific examples of offset information are provided, other suitable offsets are within the scope of the present disclosure.

[0043] In one form, the controller 114 uses the offset information to adjust the measured reference angle to calculate the calibrated reference angle. For example, for an offset associated with the tilt of the platform 104, the controller 114 subtracts or adds the offset from the measured reference angle to determine the calibrated reference angle. The controller 114 is configured to calculate the calibrated reference angle in a variety of suitable ways to take one or more of the offsets into account. If no offset information is stored, the controller 114 is configured to use the measured reference angle as the calibrated reference angle to determine whether the reference angle is within a set tolerance range.

[0044] The controller 114 uses the calibrated reference angle to determine whether the reference angle is within the set angle range, or in other words, within the set tolerance range. For example, the set angle range includes but is not limited to + / -3.0 degrees or +4.25 degrees and -1.75 degrees. In one form, the controller 114 compares the calibrated reference angle with the set angle range to determine whether the calibrated reference angle is acceptable. If the calibrated reference angle is outside the set angle range, the controller 114 is configured to output a control signal to the sensor adjustment tool to enable the tool 110 to adjust the position of the radar assembly 108. For example, if the calibrated reference angle is greater than the upper limit of the set angle range, the controller 114 operates the sensor adjustment tool to reduce the reference angle by driving the fastener 204. The controller 114 can be configured to adjust the position of the radar assembly 108 in various suitable ways. For example, the controller 114 incrementally adjusts the position with a set degree amount (e.g., 0.001 degree increments). Alternatively, the controller 114 is configured to adjust the position based on a degree of error of the calibrated reference angle 116 relative to the angular threshold range, such that the sensor adjustment tool 110 adjusts the position to compensate for the degree of error.

[0045] refer to Figure 4 , an exemplary flow chart of a sensor assembly alignment routine 400 performed by the system is provided. Prior to performing the routine 400, an operator positions the alignment gauge 112 on the sensor assembly and couples the sensor alignment tool to the fastener. At 402, the system measures a reference angle of the sensor assembly. In one form, the reference angle is measured by the alignment gauge and transmitted to the controller. Alternatively, the operator may read the reference angle from a display of the alignment gauge and input it into the controller.

[0046] At 404, the system calculates a calibrated reference angle based on the offset information and the measured reference angle, and at 406, analyzes the calibrated reference angle relative to the set angle range. At 408, the system determines whether the calibrated reference angle is within the set angle range. If the calibrated reference angle is within the set angle range, routine 400 ends. Alternatively, if the calibrated reference is outside the set angle range, the system adjusts the position of the sensor assembly at 410. For example, the controller operates a sensor adjustment tool to drive the fastener in one of the first direction or the second direction based on the error degree (or in other words, the deviation of the calibrated reference angle from the angle threshold range). Once the adjustment is made, the system returns to 402 to measure the reference angle. Through a closed-loop feedback process, the system adjusts the position until the calibrated reference angle is within the set angle range.

[0047] The sensor alignment system can be implemented as an online manufacturing process or an offline manufacturing process. The system automates the alignment process of the sensor assembly to facilitate an accurate and efficient alignment process with minimal operator error. In one form, by implementing the system as an online manufacturing process, a separate workbench is no longer required. Alternatively, the alignment system can be implemented as a stand-alone process or in conjunction with another manufacturing step. In addition, the system takes into account various offsets that may affect the alignment of the sensor assembly, thereby facilitating accurate alignment.

[0048] The description of the present disclosure is merely exemplary in nature, and therefore, variations that do not depart from the essence of the present disclosure are intended to be within the scope of the present disclosure. These variations should not be regarded as departing from the spirit and scope of the present disclosure.

[0049] According to the present invention, a method for aligning a vehicle radar assembly is provided, which comprises: measuring a reference angle of the radar assembly by an alignment gauge; transmitting the reference angle to a controller by the alignment gauge; and adjusting the position of the radar assembly based on the measured reference angle and offset information using a sensor adjustment tool that can be operated by the controller, so that the reference angle is within an angle threshold range.

[0050] According to one embodiment, the offset information includes at least one of an environmental offset, a statistical offset, and a sensor component offset.

[0051] According to one embodiment, the offset information is stored by the controller and includes one or more identified offsets that affect the angular position of the sensor assembly.

[0052] According to one embodiment, the method includes: calculating, by the controller, a calibrated reference angle based on the measured reference angle and the offset information before adjusting the position of the radar assembly, and determining, by the controller, whether the calibrated reference angle is within the angle threshold range.

Claims

1. A sensor alignment system for aligning a sensor assembly disposed along a vehicle body, the sensor assembly having a sensing surface from which a measurement signal is emitted, the sensor alignment system comprising: an alignment gauge operable to measure a reference angle of the sensor assembly, the alignment gauge having a reference surface contacting the sensing face of the sensor assembly to measure the reference angle; a sensor adjustment tool operable to adjust a position of the sensor assembly relative to the vehicle body; as well as A controller communicatively coupled to the alignment gauge and the sensor adjustment tool, wherein the controller is configured to operate the sensor adjustment tool to control the reference angle of the sensor assembly within a tolerance range based on the reference angle measured by the alignment gauge and offset information including one or more identified offsets that affect the angular position of the sensor assembly, wherein the offset information includes at least one of an environmental offset associated with a vehicle manufacturing environment, a statistical offset obtained based on data of a previous sensor assembly that was aligned, and a sensor assembly offset.

2. The system of claim 1, wherein the offset information includes environmental offsets, the environmental offsets including offsets associated with at least one of the sensor adjustment tool, the alignment gauge, and a platform on which the vehicle body is supported.

3. The system of claim 1, wherein the offset information comprises statistical offsets based on performance data of a plurality of sensor components.

4. The system of claim 1, wherein the offset information includes a sensor assembly offset based on a manufacturing offset associated with the sensor assembly.

5. The system of claim 1, wherein the controller is communicatively coupled to the alignment gauge via wireless communication.

6. The system of any one of claims 1 to 5, wherein the sensor assembly is a radar assembly and the alignment gauge comprises a fixture operable to attach to the radar assembly while the radar assembly measures the reference angle.

7. A method for aligning a sensor assembly disposed along a vehicle body, the method comprising: measuring a reference angle of the sensor assembly by an alignment gauge, wherein the alignment gauge has a reference surface and is attached to the sensor assembly such that the reference surface is in contact with a sensing surface of the sensor assembly from which a measurement signal from the sensor assembly is emitted; calculating, by a controller, a calibrated reference angle based on the measured reference angle and offset information, wherein the offset information is stored by the controller and includes one or more identified offsets that affect the angular position of the sensor assembly, wherein the offset information includes at least one of an environmental offset associated with a vehicle manufacturing environment, a statistical offset obtained based on data of previous sensor assemblies aligned, and a sensor assembly offset; as well as In response to the calibrated reference angle being outside of an angle threshold range, a position of the sensor assembly is adjusted using a sensor adjustment tool operable by the controller.

8. The method of claim 7, further comprising: The measured reference angle is transmitted to the controller by the alignment gauge via wireless communication.

9. The method of claim 7, wherein the sensor assembly is a radar assembly.

10. The method of claim 7, wherein the offset information includes environmental offsets, the environmental offsets including offsets associated with at least one of the sensor adjustment tool, the alignment gauge, and a platform on which the vehicle body is supported.

11. The method of claim 7, wherein the offset comprises a statistical offset based on performance data of a plurality of sensor assemblies.

12. The method of any one of claims 7 to 11, wherein adjusting the position of the sensor assembly further comprises: transmitting, by the controller, a control signal to the sensor adjustment tool so that the sensor adjustment tool adjusts the position of the sensor assembly based on the calibrated reference angle and the angle threshold range; as well as A fastener is driven by the sensor adjustment tool in response to receiving the control signal, the fastener attaching the sensor assembly to the vehicle body.

13. The method of claim 12, further comprising: comparing, by the controller, the calibrated reference angle with the angle threshold range; In response to the calibrated reference angle being greater than an upper limit of the angle threshold range, driving the fastener in a first direction via the sensor adjustment tool; as well as In response to the calibrated reference angle being less than a lower limit of the angle threshold range, the fastener is driven in a second direction different from the first direction by the sensor adjustment tool.

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