Cleaning liquid tank with magnetic response sensor

Abstract

The present disclosure provides a "washer fluid tank with a magnetic response sensor". A washer fluid tank assembly for mounting on a vehicle includes a tank, a track, a float, and two magnetic response sensors. The tank has a filling opening. The track is formed in a first wall of the tank and is inside the tank. The float is slidably disposed on the track and has a magnet thereon near a second wall of the tank. The magnetic response sensors are fixed to the second wall of the tank and are aligned with the track. Each of the sensors is associated with a predetermined fluid volume.

Description

Technical Field

[0001] The present invention relates to the field of vehicle cleaning fluid tank assemblies. Background Art

[0002] Autonomous vehicles and vehicles with advanced driver assistance systems (“ADAS”) can employ multiple vision sensors that provide situational awareness data to one or more controllers, including image data indicative of traffic, proximity to other vehicles, traffic control signals, traffic lane positions, and the like. Exemplary vision sensors include cameras and lidar sensors. Such vision sensors need to be kept clean to allow the vehicle to continue operating. Fluid cleaners can be used to clean these sensors. However, such systems only function when they have an available supply of cleaning fluid. Summary of the Invention

[0003] A cleaning fluid tank assembly for mounting on a vehicle includes a tank, a track, a float, and two magneto-responsive sensors. The tank has a filling opening. The track is formed in a first wall of the tank and is inside the tank. The float is slidably disposed on the track and has a magnet thereon near a second wall of the tank. The magneto-responsive sensors are fixed to the second wall of the tank and are aligned with the track. Each of the sensors is associated with a predetermined fluid volume.

[0004] The track can be defined by a guide rail, and the float is non-rotatably disposed on the guide rail.

[0005] The float can include a track groove for receiving the guide rail.

[0006] The track groove can have an open side that snaps onto the guide rail to remain on the guide rail.

[0007] The tank can further include a first part and a second part, wherein the track is formed in the first part, and the two parts are bonded together.

[0008] The first part and the second part of the tank can be injection-molded plastic moldings.

[0009] The float can be installed before the first part and the second part are bonded together.

[0010] The sensors can be bonded to the outside of the tank.

[0011] A first sensor of the sensors can be associated with a first fluid volume that is less than half of the capacity of the tank.

[0012] The second sensor in the sensor can be associated with a second fluid volume that is less than the first fluid volume.

[0013] A vehicle visibility device cleaning system includes a first tank, a first track, a first float, two magnetoresponsive sensors, a first pumping unit, a plurality of visual sensor cleaners, a windshield washer nozzle, and a controller. The first tank has a filling opening. The first track is formed in a first wall of the tank and is inside the tank. The first float is slidably disposed on the track and has a first magnet thereon near a second wall of the tank. The two magnetoresponsive sensors are fixed to the second wall of the tank and are aligned with the track. Each sensor is associated with a predetermined fluid volume. The pumping unit is connected to the tank to be in fluid communication therewith. The plurality of visual sensor cleaners are connected to the pumping unit to be in fluid communication therewith. The windshield washer nozzle is connected to the pumping unit to be in fluid communication therewith. The controller is electrically connected to the magnetoresponsive sensors, the pumping unit, the nozzle, and the cleaners.

[0014] The pumping unit can include a first pump and a second pump. The first pump can be connected to the windshield washer nozzle to be in fluid communication therewith. The second pump can be connected to the visual sensor cleaners to be in fluid communication therewith. Each pump can be connected to the tank to be in fluid communication therewith. The controller can be electrically connected to the pumps.

[0015] The cleaning system can further include a second tank, a second track, a second float, a third magnetoresponsive sensor, a third pump, and a dual filling neck. The second track can be formed in a first wall of the second tank and is inside the second tank. The second float can be slidably disposed on the second track and can have a second magnet thereon near a second wall of the second tank. The third magnetoresponsive sensor can be disposed on the second wall of the second tank. The third pump can be connected to the second tank to be in fluid communication therewith and is connected to a second plurality of visual sensor cleaners to be in fluid communication therewith. The dual filling neck can be connected to each of the first tank and the second tank.

[0016] The cleaning system can further include a vent in the second tank.

[0017] The cleaning system can further include a first tube and a second tube connecting the dual filling neck to the tank. The first tube can be disposed between the dual filling neck and the first tank. The second tube can be disposed between the dual filling neck and the second tank.

[0018] The cleaning system can further include a check valve disposed between the dual filling neck and the second tank.

[0019] The first track may include a first guide rail, and the first float is slidably disposed on the first guide rail. The second track may include a second guide rail, and the second float is slidably disposed on the second guide rail.

[0020] The first float may include a first track groove for receiving the first guide rail. The first track groove may have an open side that snaps onto the first guide rail to be retained thereon. The second float may include a second track groove for receiving the second guide rail. The second track groove may have an open side that snaps onto the second guide rail to be retained thereon.

[0021] A method of cleaning a vision sensor includes the steps of: providing a tank; providing a track; providing a float; providing a first magnetic response sensor and a second magnetic response sensor; providing a pumping unit; providing a plurality of vision sensor cleaners; providing a windshield washer nozzle; and providing a controller. The track may be formed in a first wall of the tank and inside the tank. The float may be slidably disposed on the track and may have a magnet thereon near a second wall of the tank. The first magnetic response sensor and the second magnetic response sensor may be fixed to the second wall of the tank and may be aligned with the track. Each magnetic response sensor may be associated with a predetermined volume of fluid. The pumping unit may be connected to the tank in fluid communication therewith. The plurality of vision sensor cleaners may be connected to the pumping unit in fluid communication therewith. The windshield washer nozzle may be connected to the pumping unit in fluid communication therewith. The controller may be electrically connected to the magnetic response sensors, the pumping unit, the nozzle, and the cleaners. It may be determined whether the float has moved into the sensing range of the first magnetic response sensor. When the float has not moved into the sensing range of the first magnetic response sensor, it may continue to be determined whether the float has moved into the sensing range of the first magnetic response sensor. When the float has moved into the sensing range of the first magnetic response sensor, fluid flow to the windshield washer nozzle may be restricted.

[0022] The method of cleaning the vision sensor may further include the following steps. It may be determined whether the float has moved into the sensing range of the second magnetic response sensor. When it is determined that the float has not moved into the sensing range of the second magnetic response sensor, it may continue to be determined whether the float has moved into the sensing range of the second magnetic response sensor. When it is determined that the float has moved into the sensing range of the second magnetic response sensor, the remaining fluid volume in the tank may be determined, the fluid volume required to complete the stroke may be determined, and the remaining fluid volume may be compared with the required fluid volume to determine whether there is sufficient fluid to complete the stroke. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a schematic view of an exemplary cleaning system.

[0024] Figure 2 is a perspective view of an exemplary tank assembly.

[0025] Figure 3 is Figure 2 a cross-sectional view of the tank assembly taken along the direction of arrow 3 through plane 3.

[0026] Figure 4 is Figure 2 a cross-sectional view of the tank assembly taken along the direction of arrow 4 through plane 4.

[0027] Figure 5 is a first side view of one side of an alternative embodiment of the tank assembly.

[0028] Figure 6 is Figure 5 a perspective side view of the tank side.

[0029] Figure 7 is an example flowchart of an exemplary process performed by the cleaning system. DETAILED DESCRIPTION

[0030] The relative orientations and directions set forth in this specification (e.g., up, down, bottom, forward, backward, front, rear, back, outer, inner, inward, outward, side, left, right) are not presented as limitations, but for the convenience of the reader in visualizing at least one embodiment of the structures described. Such exemplary orientations are from the perspective of an occupant sitting in a seat and facing the dashboard. In the drawings, throughout several views, like reference numerals indicate like parts.

[0031] In Figures 1 to 7Exemplary vehicle visibility device cleaning system 10 employing a first tank assembly 12 (i.e., a first washer fluid tank assembly) for washer fluid and a method of using the same are shown. Cleaning system 10 is well-suited (but not limited to) for vehicles 13 that can operate in a semi-autonomous mode (i.e., a partially autonomous mode that requires some (i.e., occasional) human driver intervention) or a fully autonomous mode (i.e., a fully autonomous mode that does not require human driver intervention). For the purposes of this disclosure, an autonomous mode is defined as an autonomous mode in which vehicle propulsion (e.g., via a powertrain including an electric motor and / or an internal combustion engine), braking, and steering are all controlled by an autonomous vehicle controller (i.e., one or more computing devices); in a semi-autonomous mode, the controller controls one or two of vehicle propulsion, braking, and steering).

[0032] As Figure 1 Schematically shown, in addition to the first tank assembly 12, system 10 may also include a second tank assembly 14 for washer fluid, i.e., a second washer fluid tank assembly. A dual fill neck 16 may be provided to allow simultaneous filling of tank assemblies 12 and 14. The dual fill neck 16 may be connected to the first tank assembly 12 by a first supply tube 18 and to the second tank assembly 14 by a second supply tube 20. A check valve 22 may be provided at one end of the second supply tube 20 to prevent fluid from the tank assembly 14 from flowing back toward the dual fill neck 16. The second tank assembly 14 may also include a vent 24 to vent air from the tank assembly 14 when the tank assembly 14 is being filled.

[0033] The tank assemblies 12, 14 may be used to supply a liquid washer fluid to vehicle windows (e.g., windshield 28 and rear window 36) and vision sensors 32, 40 (e.g., cameras, lidar). Figure 1 An exemplary arrangement is shown. The first tank assembly 12 may include a first tank 64, a first float 74, a first washer fluid sensor assembly, which may be a dual-level washer fluid sensor assembly, and a first pumping unit 42. The second tank assembly 14 may include a second tank 108, a second float 110, a second washer fluid sensor assembly, and a second pumping unit 44. The tank assemblies 12, 14 may be used to supply washer fluid to the vehicle 13's windows and vision sensors. More specifically, a windshield washer nozzle 26 may be provided to allow the washer fluid to be dispensed onto the windshield 28, and the windshield washer nozzle 26's representation in Figure 1 includes a schematic triangular spray pattern. A plurality of first vision sensor cleaners 30 may be used to clean a plurality of first vision sensors 32, such as cameras, lidar. A rear washer nozzle 34 may be provided to allow the washer fluid to be dispensed onto the rear window 36, and the rear washer nozzle 34's representation in Figure 1The representation in includes a schematic triangular spray pattern. A plurality of second vision sensor cleaners 38 can be used to clean a plurality of second vision sensors 40, such as cameras, lidar. The main difference between the first vision sensor cleaner 30 and the second vision sensor cleaner 38 lies in their association with the first tank assembly 12 and the second tank assembly 14.

[0034] Pressurized liquid cleaning fluid is supplied to the nozzle 26 and the cleaner 30 through a first pumping unit 42 of the first tank assembly 12 for fluid communication with the nozzle 26 and the cleaner 30, and is supplied to the nozzle 34 and the cleaner 38 through a second pumping unit 44 of the second tank assembly 14 for fluid communication with the nozzle 34 and the cleaner 38. The pumping units 42, 44 can each include a plurality of pumps. In the exemplary system 10, the first pumping unit 42 includes two pumps: a first pump 46 and a second pump 48. The exemplary second pumping unit 44 is shown as having a third pump 50. Each of the pumps 46, 48, 50 forms part of its respective pumping unit 42, 44, is connected to its respective tank 64, 108 for fluid communication therewith, and is connected to its respective sensor cleaner 30, 38 for fluid communication therewith.

[0035] The first pump 46 can supply pressurized cleaning fluid to the windshield washer nozzle 26 and to a first plurality of the first vision sensor cleaners 30 to clean certain sensors 32, such as a front camera and two front lidars. The second pump 48 can supply pressurized cleaning fluid to a second plurality of the first vision sensor cleaners 30 to clean other sensors among the sensors 32, such as cameras on the right and left sides of the roof. The third pump 50 disposed in the second tank assembly 14 can supply pressurized cleaning fluid to the second vision sensor cleaner 38 and the rear (i.e., rear window glass) washer nozzle 34. The cleaning fluid can be transferred from the pumps 46, 48, 50 to the nozzles 26, 34 and the cleaners 30, 38 through a plurality of fluid connection lines 52 (e.g., flexible elastomeric tubes, rigid tubes, etc.).

[0036] Components (such as the nozzles 26, 34, the cleaners 30, 38, the pumps 46, 48, 50, and the sensors 32, 40) can be electrically connected to the autonomous vehicle controller 54 through the vehicle network 56. The controller 54 and the network 56 form part of the system 10. Figure 1An exemplary network 56 is shown, which includes a plurality of electronic connectors in the form of electrical connection lines 58, such as electrical wires, which are disposed between the controller 54 and the nozzles 26, 34, the cleaners 30, 38, the pumps 46, 48, 50 and the sensors 32, 40. The vehicle network 56 may also include an Ethernet or a Controller Area Network (“CAN”) bus, etc. that constitutes the electronic connectors. The network 56 may be configured to use other wired or wireless protocols, such as Bluetooth, etc. Thus, there is no need for a wired link directly from the component to the controller 54 to provide an electronic connector between the controller 54 and the components 26, 34, 30, 38, 46, 48, 50.

[0037] The system 10 may be operated by an autonomous vehicle controller 54. The controller 54 (i.e., one or more computing devices) may be referred to as an electronic control unit, i.e., ECU, and may include a Virtual Driver System (“VDS”). The controller 54 includes at least one electronic processor and an associated memory. The memory includes one or more forms of computer-readable media and stores instructions executable by the processor for controlling the system 10, e.g., performing various system operations, including the operations disclosed herein.

[0038] The memory of the controller 54 generally also stores remote data received via various communication mechanisms. The controller 54 may also have a connection to an on-vehicle diagnostic connector such as an OBD-II connector (not shown). Via the CAN bus, OBD-II, Ethernet, and / or other wired or wireless mechanisms, the controller 54 may transmit messages to and / or receive messages from various devices in the vehicle 13, such as the pumps 46, 48, the nozzles 26, 34, and the sensors 32, 40 as described herein. Although for ease of illustration, Figure 1 the controller 54 is shown as a single controller in

[0039] it should be understood that the controller 54 may include one or more computing devices (e.g., such as known vehicle component controllers and / or computing devices dedicated to the system 10) and the various operations described herein may be performed by the one or more computing devices.

[0040] The system 10 may include environmental sensors, such as a rain sensor 60 and a temperature sensor (not shown) electrically connected to the controller 54, as described above. The system 10 may communicate with a remote base station or office 62. The remote office 62 may provide command and coordination information to the vehicle 13 equipped with the system 10, such as destination information, service station locations, scheduling instructions, etc.

[0041] As shown Figures 2 to 4 in FIG. 1, the first tank assembly 12 includes a first tank 64, which may include a first tank half-shell 66 and a second tank half-shell 68. Each of the tank half-shells 66, 68 may be an injection-molded plastic molding, where each of the half-shells 66, 68 is injection-molded from plastic, such as thermoplastic polyurethane (i.e., "TPU"). The injection mold may be formed by a pair of facing molds. The molds may receive liquid plastic under pressure. Once molded, the half-shells 66, 68 may be bonded together, for example, by heat welding, sonic welding, adhesive bonding to form the first tank 64. Alternative materials and molding techniques may include vacuum forming and ABS (acrylonitrile-butadiene-styrene) plastic sheets. When the shape of the tank 64, for example, is too complex to be formed in only two parts, the tank 64 may be formed from more than two parts 66, 68.

[0042] A filling opening 70 is provided in the tank 64 to allow a cleaning liquid to enter the tank 64. The filling opening 70 may be formed by a filling tube 72, which may be formed as part of one of the half-shells 66, 68. An exemplary filling tube 72 is shown as being formed as part of the second tank half-shell 68. The tube 72 may be integrally formed with the half-shell 68 or may be formed separately and bonded to the half-shell 68.

[0043] A float 74 is provided in the tank 64 to allow indication of the liquid level within the tank 64. The float 74 may also be formed from plastic. The float 74 is buoyant in water and water-based mixtures and other liquids used as cleaners. Exemplary float structures providing such buoyancy include, but are not limited to, forming the float 74 as a hollow, sealed housing, or a housing formed around a core of low-density material (such as polystyrene closed-cell foam), or a housing that is first molded and then filled with low-density material. The float 74 includes a float magnet 76 fixed thereto. The magnet 76 is disposed near the outer edge of the float.

[0044] The tank 64 may include a track 78 formed in a first wall 80 of the tank 64. The track 78 is provided on the inner surface of the tank 64, i.e., inside the tank 64. The track 78 may be in the form of a cylindrical guide rail 82, which is integrally formed with the wall 80 of the housing half 66. The track 78 may include a connecting web 84 that connects the guide rail 82 to the wall 80. The thickness (i.e., width) of the web 84 is less than the diameter of the guide rail 82. Each of the guide rail 82 and the web 84 may be solid or hollow.

[0045] The float 74 may have an orbital groove 86 that receives the guide rail 82 for slidably setting thereon. When the liquid level changes, the float 74 can freely move up and down along the track 78. The orbital groove 86 may be complementary in shape to the track 78 and have, for example, an annular portion 88, the size of the annular portion 88 being designed to provide a sliding fit relative to the guide rail 82, i.e., the annular portion 88 is slightly larger than the guide rail 82 to allow the float to freely translate along the guide rail 82; and an open side having a gap across the web 84 between the opposing groove edges 90. The size of the gap is designed to provide a sliding fit relative to the web 84, thereby allowing the float 74 to snap onto the track 78 for retention thereon. The annular portion 88 may extend around the center of the orbital groove 86 more than 180 degrees to the groove edge, thereby allowing the float 74 to be retained on the track 78. By aligning the gap between the edge 90 and the guide rail 82 and pressing the float 74 against the guide rail 82 to snap the float 74 onto the track 78, the float 74 can be slidably disposed on the track 78. When the float 74 is pushed against the guide rail 82, the relative elastic deflection between the guide rail 82 and the edge 90 allows the edge 90 to move around the outer circumference of the guide rail 82. After the edge 90 has passed the center of the guide rail 82, the float 74 is retained by the guide rail 82.

[0046] In Figures 3 to 6 the illustrated embodiment, the track 78 is shown as straight. However, the float 74 may be configured to accommodate a slight bend in the track 78 by, for example, forming the orbital groove 86 as part of two separate components (e.g., two C-shaped clips (not shown), a first C-shaped clip near the top of the float 74 and a second C-shaped clip near the bottom of the float 74). The gap between the float 74 and the first wall 80 may be provided by separating one side of the float 74 from the two C-shaped clips (i.e., the orbital groove portion). The space between the C-shaped clips accommodates the arch of the track 78.

[0047] The tank assembly 12 includes two liquid level sensors: a first liquid level sensor 92 and a second liquid level sensor 94. Each of the liquid level sensors 92 and 94 can be a Hall effect sensor, i.e., a magnetic response sensor that generates a signal in response to the presence of a magnet. The sensors 92, 94 can always be powered to allow their operation. The liquid level sensors 92, 94 are fixed to the outside of the second wall 96 of the tank 64 at positions associated with the track 78. When the tank 64 is in the installed orientation, the first liquid level sensor 92 is located at a first position associated with a first fluid level (i.e., a first fluid volume, e.g., which is less than half of the capacity of the tank 64). The second liquid level sensor 94 is located at a second position associated with a second fluid level (i.e., a second fluid volume). The second fluid volume is less than the first fluid volume. The first fluid volume indicates a fluid amount that can be associated with a first remaining vehicle driving distance (i.e., the distance that the vehicle 13 can travel at the current cleaning fluid consumption rate before the cleaning fluid in the tank assembly 12 is exhausted). The second fluid volume of the assembly 12 indicates a fluid amount that can be associated with a second remaining driving distance. Both sensors 92, 94 can be attached to the second wall 96 via heat melting, sonic welding, or high-viscosity glue.

[0048] The float 74 can be disposed in the float chamber 98 of the tank 64, as Figure 3 and Figure 4 shown. The height of the chamber 98 can be less than the total height of the cleaning fluid tank 64 in its installed orientation. The first wall 80 and the second wall 96 can form the sides of the chamber 98. The chamber 98 must be positioned high enough and long enough to accommodate the sensors 92, 94 placed thereon at positions that allow indication of the first volume and the second volume of the tank assembly 12. The shown chamber 98 includes a first wall 80 having a track 78 and a second wall 96 having the sensors 92, 94. The float is slidably and non-rotatably disposed on the guide rail, i.e., the engagement of the float 74 with the track 78 prevents the float 74 from rotating within the chamber, so that when the float translates up and down with the liquid level, the magnet 76 is held in a position facing the second wall 96. With the arrangement as Figure 3 and Figure 4 shown, the float magnet 76 can be placed opposite the groove 86. Alternatively, the magnet 76 can be placed on the top or bottom of the float 74, as long as a portion of the magnet 76 is close to the second wall 96, i.e., within the sensing range of the sensors 92, 94 on the second wall. Or, the first wall 80 and the second wall 96 can be at right angles, allowing the magnet 76 to be positioned at 90 degrees to the groove 86.

[0049] Sensors 92, 94 can be integrated into the dual - level cleaning fluid sensor assembly 100. The first connection strip 102 can be disposed between the first - level sensor 92 and the second - level sensor 94 and connect the first - level sensor 92 and the second - level sensor 94. The second connection strip 104 can be disposed between the second sensor 92 and the sensor connector 106 and connect the second sensor 92 and the sensor connector 106. The connector 106 can be electrically connected to each of the sensors 92, 94 through wires (not shown) that can be incorporated into the strips 102, 104. The connector 106 can receive a plug (not shown) that connects the sensors 92, 94 to the controller 54 through the network 56. The sensors 92, 94, the connection strips 102, 104, and the connector 106 can each be bonded to the wall 96 by any suitable method or mechanism, such as heat fusion, sonic welding, adhesive bonding, etc.

[0050] The dual - level cleaning fluid sensor assembly 100 allows for level sensing without any risk of fluid leakage at the sensor assembly 100, which can occur with a float - type level sensor passing through a side of the tank 64. The level sensor assembly 100 can be adapted for cleaning fluid tanks of any shape and size.

[0051] Each of the sensors 92, 94 generates a signal, such as a Hall voltage, indicating the presence of the float magnet 76 when the float magnet 76 is aligned with and within the sensing range of the sensors 92, 94. The sensing range of one of the sensors 92, 94 is a predetermined distance between the magnet 76 and the sensors 92, 94. The range can be determined based on several factors, which can include the expected temperature range, the characteristics of the sensor, and the characteristics of the magnet, including the shape of the magnet, the size of the magnet, and the field strength of the magnet. The controller 54 is programmed to: when the first - level sensor 92 provides a signal indicating the presence of magnetism, identify a signal such as indicating that the remaining fluid in the tank 64 is at a first fluid volume, and when the second - level sensor 94 provides a signal indicating the presence of magnetism, identify a signal such as indicating that the remaining fluid in the tank 64 is at a second, smaller fluid volume.

[0052] Except as expressly described herein, the second tank assembly 14 has substantially the same structure as the first tank assembly 12. For example, the second tank assembly 14 may have only one pump 50 and may include a vent 24. The second tank assembly 14 includes a second tank 108. The tank 108 may be substantially the same as the first tank 64. The second tank 108 may also be injection molded in multiple parts and assembled by bonding these parts together. The second float 110 may be similarly disposed in the second tank 108. The float 110 may be slidably disposed on the second track 111, where a second track groove (not shown) receives the second track 111. The second float 110 may include a second float magnet 112. The tank 108 may have its own first wall (not shown) and a second wall 114, where the second track 111 is disposed on the inner side of the first wall, and the second sensor assembly (not shown) is bonded to the outer side of the second wall 114. The second sensor assembly may include only one sensor, for example, a second or lower level sensor 116, and a connector and a connecting strip (not shown) disposed between the connector and the sensor 116. Alternatively, the second sensor assembly may further include a first level sensor above the second level sensor 116.

[0053] Figure 5 and Figure 6 An alternative exemplary first tank half-shell 66' is shown, which shows the flexibility of the system 10 in accommodating various tank shapes. Figure 5 and Figure 6 The reference numerals used in Figures 1 to 4 correspond to the reference numerals used in Figure 5 and Figure 6 The difference between the reference numerals used in Figures 1 to 4 and the reference numerals used in

[0054] Figure 5 The inner side of the half-shell 66' is shown. The float 74' is slidably disposed on the track 78'. The track 78' is formed on the first wall 80'. The second wall 96' is connected to the first wall 80'. The walls 80' and 96' are substantially perpendicular to each other. Thus, the float magnet 76' may be located on the float 74', at a right angle to the track groove 86' in the float 74'. With the magnet 76' and the groove 86' so positioned, the magnet 76' faces the second wall 96'.

[0055] Figure 6Shows the outer side of the half shell 66'. The dual-level windshield washer fluid sensor assembly 100' is disposed on the outer side of the second wall 96'. The assembly 100' includes a first level sensor 92' and a second level sensor 94' connected by a first connecting strip 102'. A second connecting strip 104' connects the sensors 92', 94' to the connector 106'. The assembly 100' can be different from the assembly 100 at least in terms of the distance between the sensors 92', 94' of the assembly 100' and the distance between the sensors 92, 94 of the assembly 100.

[0056] Reference Figure 7 to the flowchart of, system 10 can operate as follows.

[0057] Figure 7 Shows the windshield washer fluid level management process 130 for operating Figure 1 system 10, which is simplified by the operation not including the second tank assembly 14 to facilitate understanding of the process 130. The windshield washer fluid level management process can be stored in the controller 54. As described below, the controller 54 executes Figure 7 the exemplary steps shown in. The computer program for executing the process 130 is instantiated in the start box 132, for example, when the vehicle 13 starts to move, or when a start command is issued, such as can be associated with the vehicle 13 starting in response to a vehicle passenger or driver approaching or touching.

[0058] Next, the decision box 134 checks the signal from the first level sensor 92, such as the Hall voltage, which indicates that the float magnet 76 is substantially aligned with the sensor 92 and the liquid level is at the first level, i.e., the first fluid volume. When the signal from the first level sensor 92 has not been detected, the process 130 returns to the decision box 134 to continue checking the signal from the sensor 92. When the sensor 92 provides a signal indicating that the liquid level is at the first level, the process 130 moves to the process box 136. The process box 136 commands the system 10 to stop the fluid from flowing to the windshield washer nozzle 26 to start conserving fluid. The process box 136 can also set a first virtual switch within the controller 54, i.e., virtual switch 1 (not shown), which indicates the first low level of the fluid, i.e., the first fluid volume. The liquid level selected for the first low level of the fluid can be a low level but not an extremely low level. As long as the sensors 32, 40 on which the navigation of the vehicle 13 depends are not behind the windshield 28 or the rear window 36, a clean windshield 28 and a clean rear window 36 are not important for the continuous operation of the vehicle 13 when the vehicle 13 is operating in autonomous mode.

[0059] Process 130 continues to decision block 138, which checks the signal from the second level sensor 94, such as a Hall voltage, which indicates that the float magnet 76 is substantially aligned with the sensor 94 and the liquid level is at the second level, i.e., the second fluid volume. When the signal from the second level sensor 94 has not been detected, process 130 continues to move to decision block 140. Decision block 140 evaluates whether vehicle 13 is within a predetermined time or distance (e.g., two minutes) of a service station where a top-up can be provided, and whether the trip is a time-critical trip (e.g., an emergency transport to a hospital). When the time or distance is greater than the predetermined value, or the trip is time-critical, the trip continues and process 130 loops back to decision block 138 to continue checking the signal from sensor 94. When the expected time or distance is less than the predetermined value, and the trip is not time-critical, process 130 moves to process block 142.

[0060] Process block 142 commands vehicle 13 to travel to a service station for a top-up. Once the tank assembly 12 has been topped up with the cleaning fluid, process 130 can continue to process block 143, which commands vehicle 13 to continue the trip. Then, process 130 returns to start block 132, and the status of sensor 92 stored by the controller 54 (i.e., the virtual switch) is reset to the untriggered state.

[0061] When the signal from the second level sensor 94 provides a signal indicating that the fluid level is at the second level, process 130 moves to process block 144. Process block 144 can also set a second virtual switch within the controller 54, i.e., virtual switch 2 (not shown), which indicates the second low level of the fluid, i.e., the second level. The level selected for the second low level of the fluid can be a very low level, indicating a significantly restricted vehicle operating range. Process 130 moves from process block 144 to decision block 145.

[0062] Decision block 145 determines whether there is enough cleaning fluid remaining in the tank assembly 12 to complete the trip by estimating how much fluid the remaining trip will require and comparing it with the amount of fluid remaining in the tank assembly 12. When the float 74 (as indicated by the action of the float magnet 76 on the sensor 94) is at the second level, the remaining fluid volume is known.

[0063] Using the GPS data and the route planning function, the controller 54 can determine the value of the remaining travel distance. The remaining range available for the cleaning fluid available in the tank assembly 12 can be calculated based on any one of a number of methods. The cleaning tank assembly 12 can be equipped with a flow meter (not shown) that measures the amount of fluid leaving the tank assembly 12. The controller 54 can use the amount of fluid dispensed during a known driving period (e.g., the previous 15 minutes) to calculate the value of the amount of fluid consumed per unit time. And as long as the controller has the value of the distance traveled during the same time period, it can calculate the value of the amount of fluid consumed per unit distance. The values of both the amount of fluid consumed per unit distance and the amount of fluid consumed per unit time can vary with road and weather conditions.

[0064] An alternative method of calculating the fluid usage rate is to obtain the known volume difference between level 1 and level 2 and divide it by the number of miles traveled between the first level and the second level. However, the calculated volume value per unit mile is used to determine the remaining travel range before the cleaning fluid runs out. Multiple values of the volume per unit mile can be calculated using a variety of methods, and the highest value of the fluid volume per mile can be used for further calculations. Decision block 145 calculates the volume of fluid required to complete the current trip based on the calculated fluid usage rate. Then, decision block 145 compares the volume in the tank with the calculated volume required to complete the trip.

[0065] When decision block 145 determines that there is sufficient volume of remaining fluid to complete the trip (i.e., sufficient fluid), process 130 can move to process block 146. Process block 146 sets a service notification to replenish the cleaning fluid when the vehicle 13 returns. Then, process 130 can continue to process block 143, which commands the vehicle 13 to continue the trip. Then, process 130 returns to start block 132, and the status of sensors 92, 94 stored by the controller 54 (i.e., virtual switches 1 and 2) can be reset to the untriggered state.

[0066] When decision block 145 determines that there is not enough remaining fluid to complete the trip, process 130 continues to process block 142. As described above, process block 142 commands the vehicle 13 to go to a service station for replenishment. Once the tank assembly 12 has been replenished, process 130 can continue to move to process block 143, which commands the vehicle 13 to continue the trip. Then, process 130 returns to start block 132, and the status of sensors 92, 94 stored by the controller 54 (i.e., virtual switches 1 and 2) is reset to the untriggered state.

[0067] Exemplary tank assemblies, cleaning systems, and methods of using the same have been disclosed.

[0068] As used herein, the adverb "substantially" means that due to deficiencies in materials, processing, manufacturing, data transfer, computing speed, etc., the shape, structure, measurement, quantity, time, etc. may deviate from the geometric structures, distances, measurements, quantities, times, etc. that are precisely described.

[0069] Regarding the references to the ECU in this specification, the computing devices such as those discussed herein generally each include instructions that can be executed by one or more of the computing devices such as those listed above and are for performing the blocks or steps of the processes described above. For example, the process blocks discussed above are embodied as computer-executable instructions.

[0070] Generally, the described computing systems and / or devices can employ any of a number of computer operating systems, including but not limited to various versions or variants of the following operating systems: Ford Applications, AppLink / SmartDevice Link middleware, Microsoft Operating System, Microsoft Operating System, Unix operating systems (e.g., the operating system released by Oracle Corporation, Redwood Shores, California), the AIX UNIX operating system released by International Business Machines Corporation, Armonk, New York, Linux operating systems, the Mac OS X and iOS operating systems released by Apple Inc., Cupertino, California, the BlackBerry OS released by BlackBerry Limited, Waterloo, Canada, the Android operating system developed by Google Inc. and the Open Handset Alliance, or the CAR Infotainment Platform provided by QNX Software Systems Limited. Examples of computing devices include but are not limited to in-vehicle computers, computer workstations, servers, desktop computers, notebooks, laptop computers or handheld computers, or some other computing systems and / or devices.

[0071] Computing devices generally include computer-executable instructions, in which case the instructions can be executed by one or more computing devices (such as those listed above). The computer-executable instructions can be compiled or interpreted from computer programs created using various programming languages and / or technologies, including but not limited to Java, used alone or in combination TM, C, C++, Matlab, Simulink, Stateflow, Visual Basic, Java Script, Perl, HTML, etc. Some of these applications can be compiled and executed on virtual machines, such as Java virtual machines, Dalvik virtual machines, etc. Generally, a processor (e.g., a microprocessor) receives instructions from, for example, a memory, a computer-readable medium, etc., and executes these instructions to complete one or more processes, including one or more of the processes described herein. A variety of computer-readable media can be used to store and transmit such instructions and other data. Files in a computing device are typically a collection of data stored on a computer-readable medium (such as a storage medium, random access memory, etc.).

[0072] A computer-readable medium (also referred to as a processor-readable medium) includes any non-transitory (e.g., tangible) medium that participates in providing data (e.g., instructions) that can be read by a computer (e.g., by a processor of the computer). Such a medium can take many forms, including but not limited to non-volatile media and volatile media. Non-volatile media can include, for example, optical or magnetic disks and other persistent memories. Volatile media can include, for example, dynamic random access memory (DRAM), which typically constitutes main memory. Such instructions can be transmitted through one or more transmission media, including coaxial cables, copper wire, and fiber optics, including the wires that make up a system bus coupling to a processor of an ECU. Common forms of computer-readable media include, for example, floppy disks, flexible disks, hard disks, magnetic tape, any other magnetic medium, CD-ROM, DVD, any other optical medium, punch cards, paper tape, any other physical medium with a hole pattern, RAM, PROM, EPROM, FLASH-EEPROM, any other memory chip or cartridge, or any other medium from which a computer can read.

[0073] The databases, data warehouses, or other data storage devices described herein can include various mechanisms for storing, accessing, and retrieving various data, including hierarchical databases, a set of files in a file system, application databases in proprietary formats, relational database management systems (RDBMSs), etc. Each such data storage device is typically included in a computing device employing a computer operating system, such as one of the operating systems mentioned above, and is accessed via a network in any one or more of a variety of ways. A file system can be accessed from a computer operating system and can include files stored in various formats. In addition to languages for creating, storing, editing, and executing stored procedures, an RDBMS typically also uses a structured query language (SQL), such as the PL / SQL language mentioned above.

[0074] In some examples, system components may be implemented as computer-readable instructions (e.g., software) on one or more computing devices (e.g., servers, personal computers, etc.) and stored on a computer-readable medium associated therewith (e.g., disks, memories, etc.). A computer program product may include instructions stored on a computer-readable medium for performing the functions described herein.

[0075] Regarding the media, processes, systems, methods, heuristics, etc. described herein, it should be understood that although the steps of such processes, etc. have been described as occurring in a particular order, such processes may be implemented by performing the steps in an order different from that described herein. It should also be understood that certain steps may be performed simultaneously, other steps may be added, or certain steps described herein may be omitted. In other words, the description of the processes herein is provided to illustrate certain embodiments and should in no way be construed as limiting the claims.

[0076] The present disclosure has been described in an illustrative manner, and it should be understood that the terms used are of a descriptive nature rather than a restrictive nature. Given the above teachings, many modifications and variations of the present disclosure are possible, and the present disclosure may be practiced in a manner different from that specifically described.

[0077] According to the present invention, there is provided a windshield washer fluid tank assembly for mounting on a vehicle, having: a first tank having a filling opening; a first track formed in a first wall of the tank and inside the tank; a first float slidably disposed on the track and having a magnet thereon proximate a second wall of the tank; and two magnet-responsive sensors fixed to the second wall of the tank, aligned with the track, and each sensor associated with a predetermined fluid volume.

[0078] According to one embodiment, the track is defined by a guide rail, and the float is non-rotatably disposed on the guide rail.

[0079] According to one embodiment, the float includes a track groove for receiving the guide rail.

[0080] According to one embodiment, the track groove has an open side that snaps onto the guide rail to be retained thereon.

[0081] According to one embodiment, the above invention is further characterized by a first part and a second part, wherein the track is formed in the first part, and the two parts are bonded together.

[0082] According to one embodiment, the first part and the second part are injection-molded plastic moldings.

[0083] According to one embodiment, the float is installed before the first part and the second part are bonded together.

[0084] According to one embodiment, the sensor is bonded to the outside of the tank.

[0085] According to one embodiment, a first sensor among the sensors is associated with a first fluid volume that is less than half of the tank capacity.

[0086] According to one embodiment, a second sensor among the sensors is associated with a second fluid volume that is less than the first fluid volume.

[0087] According to the present invention, there is provided a vehicle visibility cleaning system having: a first tank having a filling opening; a first track formed in a first wall of the tank and inside the tank; a first float slidably disposed on the track and having a first magnet thereon near a second wall of the tank; and two magnetoresistive sensors fixed to the second wall of the tank, aligned with the track, and each sensor associated with a predetermined fluid volume; a pumping unit connected to the tank in fluid communication therewith; a plurality of visual sensor cleaners connected to the pumping unit in fluid communication therewith; a windshield washer nozzle connected to the pumping unit in fluid communication therewith; and a controller electrically connected to the magnetoresistive sensors, the pumping unit, the nozzle, and the cleaners.

[0088] According to one embodiment, the above invention is further characterized in that the pumping unit includes a first pump and a second pump, the first pump is connected to the windshield washer nozzle in fluid communication therewith, and the second pump is connected to the visual sensor cleaners in fluid communication therewith, and each pump is connected to the tank in fluid communication therewith, and the controller is electrically connected to the pumps.

[0089] According to one embodiment, the above invention is further characterized in that: a second tank; a second track formed in a first wall of the second tank and inside the second tank; a second float slidably disposed on the second track and having a second magnet thereon near a second wall of the second tank; a third magnetoresistive sensor disposed on the second wall of the second tank; a third pump connected to the second tank in fluid communication therewith and connected to a second plurality of visual sensor cleaners in fluid communication therewith; and a dual filling neck connected to each of the first tank and the second tank.

[0090] According to one embodiment, the above invention is further characterized in that there is a vent in the second tank.

[0091] According to one embodiment, the features of the above invention further lie in a first pipe and a second pipe, the first pipe and the second pipe connecting the double filling neck to the tank, wherein the first pipe is disposed between the double filling neck and the first tank, and the second pipe is disposed between the double filling neck and the second tank.

[0092] According to one embodiment, the features of the above invention further lie in a check valve disposed between the double filling neck and the second tank.

[0093] According to one embodiment, the first track includes a first guide rail, the first float being slidably disposed on the first guide rail, and the second track includes a second guide rail, the second float being slidably disposed on the second guide rail.

[0094] According to one embodiment, the first float includes a first track groove for receiving the first guide rail, and the first track groove has an open side that snaps onto the first guide rail to be retained on the first guide rail; and the second float includes a second track groove for receiving the second guide rail, and the second track groove has an open side that snaps onto the second guide rail so as to be retained on the second guide rail.

[0095] According to the present invention, a method for cleaning a vision sensor includes the following steps: providing a tank; providing a track formed in a first wall of the tank and inside the tank; providing a float slidably disposed on the track and having a magnet near a second wall of the tank; providing a first magnetic response sensor and a second magnetic response sensor, wherein each sensor is fixed to the second wall of the tank and aligned with the track, and each of the magnetic response sensors is associated with a predetermined fluid volume. Providing a pumping unit connected to the tank for fluid communication therewith; providing a plurality of vision sensor cleaners connected to the pumping unit for fluid communication therewith; providing a windshield washer nozzle connected to the pumping unit for fluid communication therewith; and providing a controller electrically connected to the magnetic response sensors, the pumping unit, the nozzle, and the cleaners; determining whether the float has moved into the sensing range of the first magnetic response sensor; when the float has not moved into the sensing range of the first magnetic response sensor, continuing to determine whether the float has moved into the sensing range of the first magnetic response sensor; and when the float has moved into the sensing range of the first magnetic response sensor, restricting fluid flow to the windshield washer nozzle.

[0096] According to one embodiment, the features of the above invention further lie in the following steps: determining whether the float has moved into the sensing range of the second magnetic response sensor; when the float has not moved into the sensing range of the second magnetic response sensor, continuously determining whether the float has moved into the sensing range of the second magnetic response sensor; and when the float has moved into the sensing range of the second magnetic response sensor, determining the remaining fluid volume in the tank, determining the fluid volume required to complete the stroke, and comparing the remaining fluid volume with the required fluid volume to determine whether there is sufficient fluid to complete the stroke.

Claims

1. A vehicle visibility device cleaning system, comprising: A cleaning liquid tank assembly for installation on a vehicle, which includes: A first tank having a filling opening; A first track formed in a first wall of the first tank and inside the first tank; A first float slidably disposed on the first track and having a first magnet thereon near a second wall of the first tank; and A first magnetic response sensor and a second magnetic response sensor fixed to the second wall of the first tank, aligned with the first track, and the first magnetic response sensor is associated with a first fluid volume, the second magnetic response sensor is associated with a second fluid volume, wherein the second fluid volume is less than the first fluid volume; A pumping unit connected to the first tank in fluid communication therewith; A windshield washer nozzle and a plurality of vision sensor cleaners each connected to the pumping unit in fluid communication therewith; A controller electrically connected to the first magnetic response sensor, the second magnetic response sensor, the pumping unit, the nozzle, and the cleaner, the controller configured to: In response to the first float having moved into the sensing range of the second magnetic response sensor, determine the remaining fluid volume in the first tank, determine the fluid volume required to complete a stroke, and compare the remaining fluid volume with the required fluid volume to determine if there is sufficient fluid to complete the stroke.

2. The cleaning system according to claim 1, wherein the first track is defined by a first guide rail, and the first float is non-rotatably disposed on the first guide rail.

3. The cleaning system according to claim 2, wherein the first float includes a first track groove for receiving the first guide rail.

4. The cleaning system according to claim 3, wherein the first track groove has a first open side that snaps onto the first guide rail to be retained thereon.

5. The cleaning system according to claim 1, the first tank further includes a first part and a second part, wherein the first track is formed in the first part, and the two parts are bonded together.

6. The cleaning system according to claim 1, wherein the first magnetic response sensor and the second magnetic response sensor are bonded to the outside of the first tank.

7. The cleaning system according to claim 1, wherein the first fluid volume is less than half of the capacity of the first tank.

8. The cleaning system according to claim 1, the pumping unit includes a first pump and a second pump, the first pump is connected to the windshield washer nozzle in fluid communication therewith, and the second pump is connected to the vision sensor cleaner in fluid communication therewith, and each pump is connected to the first tank in fluid communication therewith, and the controller is electrically connected to the pumps.

9. The cleaning system according to claim 1, further comprising: A second tank; A second track formed in a first wall of the second tank and inside the second tank; A second float slidably disposed on the second track and having a second magnet thereon near a second wall of the second tank; A third magnetic response sensor disposed on the second wall of the second tank; A third pump, which is connected to the second tank in fluid communication therewith and is connected to a second plurality of visual sensor cleaners in fluid communication therewith; and A dual fill neck, which is connected to each of the first tank and the second tank.

10. The cleaning system according to claim 9, further comprising a first pipe and a second pipe, the first pipe and the second pipe connecting the dual fill neck to the first tank and the second tank, wherein the first pipe is disposed between the dual fill neck and the first tank, and the second pipe is disposed between the dual fill neck and the second tank.

11. The cleaning system according to claim 10, further comprising a check valve disposed between the dual fill neck and the second tank.

12. A method of cleaning a visual sensor, the method comprising the steps of: Providing the cleaning system according to claim 1; Determining whether the first float has moved into the sensing range of the first magnetic response sensor; When the first float has not moved into the sensing range of the first magnetic response sensor, continuing to determine whether the first float has moved into the sensing range of the first magnetic response sensor; and When the first float has moved into the sensing range of the first magnetic response sensor, restricting fluid flow to the windshield washer nozzle.

13. The method according to claim 12, further comprising the steps of: Determining whether the first float has moved into the sensing range of the second magnetic response sensor; When the first float has not moved into the sensing range of the second magnetic response sensor, continuing to determine whether the first float has moved into the sensing range of the second magnetic response sensor; and When the first float has moved into the sensing range of the second magnetic response sensor, determining the remaining fluid volume in the first tank, determining the fluid volume required to complete a journey, and comparing the remaining fluid volume with the required fluid volume to determine whether there is sufficient fluid to complete the journey.

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