Method and system for detecting misalignment of a front-end accessory drive belt

Abstract

The present disclosure provides a "method and system for detecting misalignment of a front-end accessory drive belt." The present disclosure relates to a method for detecting misalignment of a belt of a front-end accessory drive system. The method includes: acquiring, by a plurality of optical sensors, a plurality of images of the belt arranged on a series of pulleys of the drive system. The belt includes a contrast element that is detectable by the optical sensors and is visually different in color from the belt. The method also includes: analyzing, by a controller, data indicative of the acquired images to determine whether the contrast element is present in the captured images; and identifying the belt as misaligned in response to the contrast element being in at least one of the acquired images.

Description

Technical Field

[0001] The present disclosure relates to methods and systems for detecting misalignment of a front end accessory drive belt. Background Art

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

[0003] The front end (i.e., engine) accessory drive (FEAD) system includes a belt (e.g., a serpentine belt) that drives components such as the alternator, water pump, and A / C compressor from the crankshaft pulley. During the manufacture of the FEAD system, the belt is typically installed manually and visually inspected by an operator for misalignment.

[0004] Slight misalignments can be difficult to detect by manual inspection. Specifically, if the belt is misaligned so that it rubs against the housing of the FEAD system or hangs over the rim of the pulley, the belt may produce noise during vehicle operation and / or begin to wear more quickly. The present disclosure addresses these and other issues. 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, the present disclosure is directed to a method for detecting misalignment of a belt of a front-end accessory drive system. The method includes acquiring, via a plurality of optical sensors, a plurality of images of the belt disposed on a series of pulleys of the drive system. The optical sensors are disposed external to the drive system, and the belt includes a contrast element that is detectable by the optical sensor system and is visually different in color from the belt. The method also includes analyzing, via a controller, data indicative of the acquired images to determine whether the contrast element is present in the captured images; and identifying the belt as misaligned in response to the contrast element being present in at least one of the acquired images.

[0007] In another form the optical sensor is a digital camera and the digital camera is arranged to capture images of different viewpoints of the belt at one or more pulleys of the drive system.

[0008] In yet another form, the contrasting element is a color feature detectable by the optical sensor and disposed in or on the belt.

[0009] In one form, acquiring the plurality of images further comprises causing a first optical sensor to acquire a first image of a first pulley in the series of pulleys with the belt disposed on the first pulley to assess misalignment of the belt relative to the first pulley, wherein the first camera is positioned to capture images of a rim of the first pulley and a first surface of the belt.

[0010] In another form, analyzing the acquired image further includes determining whether the contrast element is present in the first image, wherein the contrast element is disposed within the belt and is detectable by the first camera when the belt is positioned on the rim.

[0011] In one form, the method further comprises bringing the drive system to a standstill.

[0012] In another form, the method further includes estimating a strain level of the belt in response to determining that the contrast element is present in the acquired image. The contrast element is color-signaled based on a change in the amount of strain applied to the belt due to the misalignment, and the strain level estimate is based on a color of the contrast element and pre-stored data associating different colors with predefined strain levels.

[0013] In another form, identifying the belt as misaligned further comprises determining that the belt is misaligned when the amount of strain is greater than or equal to a strain threshold.

[0014] In one form, acquiring the plurality of images further comprises causing a first camera of the image sensor system to acquire a first image of a front face of a first pulley to assess misalignment of the belt relative to a seat of the first pulley on which the belt is positioned.

[0015] In another form, analyzing the acquired image further comprises determining whether the contrast element is present along an edge of the belt. The contrast element is disposed along the edge of the belt and is detectable by the first camera when the belt is positioned offset from the seat of the first pulley and is undetectable when the belt is aligned with the seat of the first pulley.

[0016] In yet another form, the method further includes installing the belt on a drive system for a vehicle.

[0017] In one form, the method further includes generating and outputting a notification in response to the belt being misaligned.

[0018] In one form, the present disclosure relates to an alignment detection system for detecting misalignment of a belt mounted on a front end accessory drive (FEAD) system. The alignment detection system includes a plurality of digital cameras and a controller. The plurality of digital cameras are arranged to capture images of the belt arranged on a plurality of pulleys of the FEAD system. The digital cameras are configured to detect a contrast element on the belt, and the contrast element is visible to the digital cameras and visually distinct from the belt. The controller is configured to process data indicative of the captured images to determine whether the belt is misaligned on the FEAD system. The controller determines that the belt is misaligned in response to the contrast element being captured in one or more images, and determines that the belt is aligned in response to the contrast element not being present in the captured images.

[0019] In another form, one or more of the plurality of digital cameras is arranged to capture images of a front face of one or more of the plurality of pulleys of the FEAD system to detect misalignment of the belt relative to the one or more pulleys. The controller is configured to determine that the belt is misaligned in response to detecting the contrast element along an edge of the belt in at least one image captured by the one or more digital cameras.

[0020] In yet another form, one or more of the plurality of digital cameras is arranged to capture images of a rim of one or more of the plurality of pulleys and a first surface of the belt disposed on the one or more pulleys, the first surface being opposite a second surface of the belt that contacts a surface of a corresponding one of the one or more pulleys.

[0021] In one form, the controller is configured to determine that the belt is misaligned in response to detecting the contrast element at the first surface of the belt in at least one image captured by the one or more digital cameras.

[0022] In another form, the digital camera is arranged to capture an image of a planar side of the belt at one or more of the plurality of pulleys. The belt has a ribbed side opposite the planar side, and the ribbed side is in contact with the one or more pulleys.

[0023] In one form, the present disclosure relates to a belt misalignment detection method for a vehicle. The method includes capturing images of a belt disposed on a plurality of pulleys of an accessory drive system with a plurality of digital cameras, wherein the belt includes a contrast element visible to the cameras; analyzing data indicative of the images to determine whether the contrast element is present in the captured images; and identifying the belt as misaligned when the contrast element is detected in at least one of the images.

[0024] In another form, the method further comprises arranging one or more of the plurality of digital cameras to capture an image of a planar side of the belt at one or more of the plurality of pulleys, the belt having a ribbed side opposite the planar side, and the ribbed side contacting the one or more pulleys.

[0025] In yet another form, the contrast element is a color feature detectable by the digital camera and is disposed in or on the belt.

[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 An alignment detection system for detecting the alignment of a belt mounted on a FEAD system according to the teachings of the present disclosure is shown;

[0029] Figure 2 is a partial cross-sectional view of a belt according to the teachings of the present invention;

[0030] Figure 3A and Figure 3B 1. The aligned state and the misaligned state of the belt in the first example according to the teachings of the present disclosure are respectively shown;

[0031] Figure 4A and Figure 4B 10 respectively show an aligned state and a misaligned state of a belt in a second example according to the teachings of the present disclosure;

[0032] Figure 5 yes Figure 1 Functional block diagram of a controller of an alignment detection system; and

[0033] Figure 6 is an exemplary belt alignment detection routine performed by an alignment detection system according to the teachings of the present disclosure.

[0034] 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

[0035] 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.

[0036] refer to Figure 1 A front end accessory drive (FEAD) system 100 provides power to a plurality of accessory components within a vehicle, such as an alternator, an A / C compressor, a power steering pump, and a water pump. In one form, the FEAD system 100 includes a drive pulley 102 (i.e., a crankshaft / drive damper), a plurality of accessory pulleys 104, and a belt 106 (i.e., a serpentine belt) wound around the drive pulley 102 and the accessory pulleys 104. Typically, in operation, the drive pulley 102 drives the belt 106, which in turn drives the accessory pulleys 104 to provide power to the accessory components.

[0037] refer to Figure 2 , the drive belt 106 includes a ribbed side 202 and a flat (smooth) side 204. The belt 106 is typically made of rubber (such as ethylene propylene diene monomer (EPDM) or neoprene) and may include two or more layers. For example, in one form, the belt 106 includes fibers (not shown) on one or both sides of the belt 106, and a rubber layer is molded over the fibers.

[0038] Continue to refer Figure 1 , the drive pulley 102 and the accessory pulley 104 may be collectively referred to as pulleys 102 and 104. The pulleys 102 and 104 define a seat 108 along which the belt 106 travels. Some of the pulleys 102 and 104 may have a smooth seat 108, while other pulleys may have a seat 108 that includes ridges that engage the ribs of the ribbed side 202 of the belt 106. During installation, the belt 106 may be misaligned with the pulley, causing the ribbed side 202 of the belt 106 to be offset from the pulley's seat. For example, if the pulley has a flanged rim, the belt 106 may be positioned so that the ribs of the belt 106 are positioned on the flanged rim of the pulley rather than resting on the pulley's seat. In another example, the belt 106 is misaligned when the ribbed side 202 of the belt 106 deviates from the ridges provided on the pulley seat, causing the belt 106 to hang over the front of the pulley or sit far behind to ride across the surface of the housing 110 of the FEAD system 100.

[0039] To detect such misalignment, an alignment detection system 120 is configured to determine whether the belt 106 is misaligned. The alignment detection system 120 may be implemented as part of the manufacturing process of the FEAD system 100 or may be provided at a service dealer that performs maintenance on the FEAD system 100. In one form, the alignment detection system 120 includes one or more optical sensors 122 (such as a digital camera), a controller 124, and one or more user interfaces 126. The optical sensors 122 are arranged to capture multiple images of the belt 106 disposed on the pulleys 102 and 104 of the FEAD system 100. In one form, the optical sensors 122 are attached to one or more fixtures disposed externally to the FEAD system 100 and have an adjustable orientation and focus.

[0040] In one form, the controller 124 is a computer having a processor, memory (e.g., RAM and / or ROM) storing computer-readable instructions executable by the processor. The controller 124 is communicatively coupled to the optical sensor 122 and the user interface 126 via a wired and / or wireless communication link to respectively acquire data indicative of an image captured by the optical sensor 122 and communicate with an operator. The controller 124 is configured to analyze the data to determine whether the belt 106 is misaligned in accordance with the teachings of the present disclosure.

[0041] More specifically, refer to Figure 2 Drive belt 106 also includes contrasting elements 206A and 206B, collectively referred to as contrasting elements 206. Contrast elements 206 are visible to optical sensor 122 and have a color different from that of belt 106. Contrast elements 206A are positioned within belt 106 such that a layer of contrasting elements 206A is positioned just below the surface of the rubber material. Contrast elements 206A can be positioned within belt 106 in various suitable ways. For example, contrasting elements 206A can extend along the entire length of belt 106, as on element 206A. Alternatively, belt 106 can include multiple contrasting elements 206A distributed in segments along the length of belt 106. Furthermore, contrasting elements 206A are positioned adjacent to at least one of ribbed side 202 or planar side 204. In other words, contrasting elements 206 are positioned close to the outer surface of at least one of ribbed side 202 or planar side 204.

[0042] Contrast elements 206B are provided along one or both of the edges 210 of the belt 106. In one form, the contrast elements 206B are provided directly on the surface of the edge 210. For example, a fluid (e.g., liquid paint or powder) is applied to the edge 210 to form the contrast elements 206B. The contrast elements 206B may extend along the entire length of the belt 106 or may be distributed along the length in a segmented manner such that the belt 106 includes a plurality of contrast elements 206B.

[0043] While belt 106 is shown as having both contrasting elements 206A and 206B, belt 106 may include only one of contrasting elements 206A or 206B. Furthermore, in one form, contrasting element 206 is provided as a color different from the color of belt 106. In another form, contrasting element 206 may have a color that changes based on the level of strain applied to belt 106. For example, contrasting element 206 may include multiple layers of different colors, each color being visible when belt 106 experiences a specific level of strain associated with that color.

[0044] The alignment detection system 120 determines whether the belt 106 is misaligned based on the visibility of the contrast element 206 via the optical sensor 122. More specifically, the optical sensor 122 is arranged to capture different viewpoints of the belt 106 disposed at one or more of the pulleys 102 and 104, such that at a particular viewpoint, if the belt 106 is aligned with the pulleys, the contrast element 206 is not visible, and when the belt 106 is misaligned, the contrast element 206 is visible. For example, referring to Figure 3A and Figure 3B , the optical sensor is arranged to capture an image of the front face 304 of the pulley 306. The pulley 306 can be either of the pulleys 102 and 104. The optical sensor is angled to detect the position of the belt 106 relative to the front face 304 and the surface of the housing 110. For example, when the belt 106 is properly aligned, the belt 106 is positioned within the seat defined by the pulley 304 so that the edge 210 of the belt 106 is behind the front face 304 and does not contact the housing 110, as shown in FIG. Figure 3A As shown. Therefore, the contrasting element 206B provided on the edge 210 is not visible, and the belt 106 is not pulled tight by the pulley 306 to expose the contrasting element 206A provided within the belt 106. In contrast, when the belt 106 is misaligned, the belt 106 may overlap the edge / rim of the pulley 306 to hang above the front face 302, thereby exposing the edge 210 of the belt 106, as shown. Figure 3BAlternatively, the belt 106 may be positioned proximate to the housing 110 such that the belt 106 overlaps the housing 110, thereby exposing the edge 210 closest to the housing 110. Thus, when the belt 106 is misaligned, the optical sensor detects at least the contrast elements 206B disposed about the edge 210.

[0045] refer to Figure 4A and Figure 4B , in another example, the optical sensor is arranged to capture an image of the pulley 404 at an angle perpendicular to the front of the pulley 404 (e.g., top view, bottom view). The pulley 404 can be any of the pulleys 102 and 104. The optical sensor is angled to detect the surface of the belt 106 and the position of the belt 106 relative to the seat, or more specifically, relative to the edge 406 of the belt 404. For example, when the belt 106 is properly aligned, the belt 106 is positioned within the seat of the pulley 404 such that the belt 106 is positioned behind the rim 406. Therefore, the belt 106 is not pulled tight by the edge 406 to expose the contrast element 206A disposed within the belt 106. In contrast, when the belt 106 is misaligned, as Figure 4B As shown, the belt 102 may overlap the rim 406 of the pulley 404, such that the belt 102 is strained by the rim 404. The strain exposes the contrast element 206A disposed within the belt 106 and is therefore detectable by the optical sensor 402.

[0046] Other arrangements of optical sensors for detecting misalignment of the belt 106 with one or more pulleys 102 and 104 are also within the scope of the present disclosure and should not be limited to the examples provided herein. Specifically, the optical sensors can be arranged in a variety of ways to capture different viewpoints based on the position and potential misalignment of the belt 106 at various pulleys. For example, multiple cameras can be used to capture different angles of the belt 106 arranged on a single pulley, or a single camera can be used to capture the belt 106 arranged on multiple pulleys.

[0047] Once the images are captured, the controller 124 analyzes the images to determine whether the contrast element 206 is present in one or more of the images. In one form, the controller 124 is configured to use known image processing techniques that analyze data from the optical sensor 122 to determine whether the contrast element 206 is present in any of the captured images. More specifically, because the contrast element 206 is provided as a color different from the color of the belt 102, the pixel value data for the contrast element 206 is different from the pixel value data for the color of the belt 106 and can therefore be distinguished by the controller 124.

[0048] For example, in one form, Figure 5An exemplary functional block diagram of the controller 124 is shown, wherein the controller 124 includes an image data enhancer 502, a contrast element detector 504, and an alignment assessment module 506. The image data enhancer 502 performs one or more enhancement processes on the acquired image data to, for example, remove noise, enhance pixel-to-pixel contrast to detect relevant information, and / or scale the data. The enhanced image data is then provided to the contrast element detector 504.

[0049] Contrast element detector 504 analyzes the enhanced image data to determine whether the image depicts contrast element 206. For example, in one form, contrast element detector 504 compares the received data to a pixel value or range of pixel values ​​associated with the color of contrast element 206. If one or more image data falls within the range, contrast element detector 504 determines that contrast element 206 is present in the captured image or images. If none of the data falls within the range, contrast element detector 504 determines that contrast element 206 is not present in the image. Other methods for enhancing and detecting contrast element 206 may also be implemented, such as pattern recognition, and are also within the scope of the present disclosure.

[0050] Based on the output of contrast element detector 504, alignment assessment module 506 determines whether belt 106 is misaligned and outputs a notification. Specifically, if contrast element 206 is present, alignment assessment module 506 determines that belt 106 is misaligned and outputs a notification of misalignment via user interface 126. Based on the misalignment, the operator can reinstall the belt or install a new belt on the FEAD system. Once installed, any possible misalignment of the belt of FEAD system 100 is rechecked in accordance with the teachings of the present disclosure. Thus, once detected, misalignment can be addressed during manufacturing.

[0051] Conversely, if the comparison element 206 is not detected, the alignment assessment module 506 determines that the belt 106 is aligned and outputs a notification that the belt 106 is aligned, or alternatively, does not output a notification. The alignment assessment module 506 may also store the determination in the memory of the controller 124 as part of the part history of the FEAD system being assembled.

[0052] In one form, if the contrast element 206 is configured to project different colors based on the strain applied to the belt 106, the controller 124 can be configured to estimate the strain level of the belt 106. For example, the controller may include pre-stored data that associates different colors of the contrast element 206 with predefined strain levels. The controller 124 is configured to determine the color of the contrast element 206 based on the pre-stored information and then determine the strain level. Furthermore, the controller 124 can be configured to identify the belt 106 as misaligned when the strain indicated by the color of the contrast element 206 is greater than or equal to a certain threshold. That is, if the contrast element is visible, the controller 124 identifies the belt 106 as misaligned when the strain level is above, for example, 10% or some other suitable value.

[0053] refer to Figure 6 , an exemplary belt alignment detection routine 600 for a FEAD system is provided. Routine 600 is executed by the alignment detection system 120 of the present disclosure and begins when the belt 106 is mounted on the FEAD system 100 and the system 100 is at rest. At 602, the system acquires one or more images of the belt mounted on the FEAD system from an optical sensor. At 604, the system uses suitable image processing techniques to analyze data indicative of the images to extract, or in other words, identify, a contrasting element in the image. At 606, the system determines whether a contrasting element is present in the one or more images. If a contrasting element is present, the system identifies the belt as misaligned at 608 and outputs a misalignment notification. Once notified, the operator can resolve the misalignment by installing a new belt or reinstalling the misaligned belt before transferring the FEAD system from the unit. If a contrasting element is not present, the system identifies the belt as aligned at 610 and outputs a normal notification. From this point, the FEAD system can be transferred to the next unit on the production line. For example, the notification may include a message displayed on a monitor, an audio notification, turning on a light indicator (such as a red light for misaligned and a green light for normal), or other suitable notification methods.

[0054] The disclosed method and system provide automated misalignment detection for belts installed on a FEAD system. For example, because the belt's edges lie out of plane and are visible to the optical sensor, small misalignments can be detected, such as a six-ribbed belt installed with one or two ribs out of position. Larger misalignments, where the belt is subject to strain due to pressure applied by pulleys, can also be detected by placing contrast elements within the belt. Once a belt is identified as misaligned, measures can be taken to realign the belt during installation.

[0055] The description of the present disclosure is merely exemplary in nature and, thus, variations that do not depart from the essence of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be regarded as a departure from the spirit and scope of the present disclosure.

[0056] According to the present invention, a method for detecting misalignment of a belt of a front-end accessory drive system is provided by: acquiring, by a plurality of optical sensors, a plurality of images of the belt arranged on a series of pulleys of the drive system, wherein the optical sensors are disposed external to the drive system and the belt includes a contrast element that is detectable by the optical sensors and that is visually different in color from the belt; analyzing, by a controller, data indicative of the acquired images to determine whether the contrast element is present in the captured images; and identifying the belt as misaligned in response to the contrast element being in at least one of the acquired images.

[0057] According to one embodiment, the optical sensor is a digital camera and the digital camera is arranged to capture images of different viewpoints of the belt at one or more pulleys of the drive system.

[0058] According to one embodiment, the contrast element is a color feature detectable by the optical sensor and provided in or on the belt.

[0059] According to one embodiment, acquiring the plurality of images further comprises causing a first optical sensor to acquire a first image of a first pulley in the series of pulleys with the belt arranged on the first pulley to assess misalignment of the belt relative to the first pulley, wherein the first camera is positioned to capture images of a rim of the first pulley and a first surface of the belt.

[0060] According to one embodiment, analyzing the acquired image further comprises determining whether the contrast element is present in the first image, wherein the contrast element is arranged within the belt and is detectable by the first camera when the belt is positioned on the rim.

[0061] According to one embodiment, the invention is further characterized in that the drive system is brought to a standstill.

[0062] According to one embodiment, the present invention is further characterized by estimating a strain level of the belt in response to determining that the contrast element is present in the acquired image, wherein the contrast element is based on a color characteristic of a change in the amount of strain applied to the belt due to the misalignment, and the estimation of the strain level is based on the color of the contrast element and pre-stored data that associates different colors with predefined strain levels.

[0063] According to one embodiment, identifying the belt as misaligned further comprises: determining that the belt is misaligned when the strain amount is greater than or equal to a strain threshold.

[0064] According to one embodiment, acquiring the plurality of images further comprises causing a first camera of the image sensor system to acquire a first image of a front face of a first pulley to assess misalignment of the belt relative to a seat of the first pulley on which the belt is positioned.

[0065] According to one embodiment, analyzing the acquired image further comprises determining whether the contrast element is present along an edge of the belt, wherein the contrast element is disposed along the edge of the belt and is detectable by the first camera when the belt is positioned offset from the seat of the first pulley and is undetectable when the belt is aligned with the seat of the first pulley.

[0066] According to one embodiment, the invention is further characterized in that the belt is mounted on a drive system for a vehicle.

[0067] According to one embodiment, the invention is further characterized by generating and outputting a notification in response to the belt being misaligned.

[0068] According to the present invention, an alignment detection system for detecting misalignment of a belt mounted on a front end accessory drive (FEAD) system is provided, the alignment detection system having: a plurality of digital cameras arranged to capture images of the belt arranged on a plurality of pulleys of the FEAD system, wherein the digital cameras are configured to detect a contrast element on the belt that is visible to the digital cameras and visually distinct from the belt; and a controller configured to process data indicative of the captured images to determine whether the belt is misaligned on the FEAD system, wherein the controller determines that the belt is misaligned in response to the contrast element being captured in one or more images, and determines that the belt is aligned in response to the contrast element not being present in the captured images.

[0069] According to one embodiment, one or more of the plurality of digital cameras are arranged to capture images of the front of one or more of the plurality of pulleys of the FEAD system to detect misalignment of the belt relative to the one or more pulleys, and the controller is configured to determine that the belt is misaligned in response to detecting the contrast element along an edge of the belt in at least one image captured by the one or more digital cameras.

[0070] According to one embodiment, one or more digital cameras of the plurality of digital cameras are arranged to capture images of a rim of one or more pulleys of the plurality of pulleys and a first surface of the belt arranged on the one or more pulleys, wherein the first surface is opposite to a second surface of the belt and the second surface is in contact with a surface of a corresponding pulley of the one or more pulleys.

[0071] According to one embodiment, the controller is configured to determine that the belt is misaligned in response to detecting the contrast element at the first surface of the belt in at least one image captured by the one or more digital cameras.

[0072] According to one embodiment, the digital camera is arranged to capture an image of a planar side of the belt at one or more of the plurality of pulleys, wherein the belt has a ribbed side opposite to the planar side, and the ribbed side is in contact with the one or more pulleys.

[0073] According to the present invention, a belt misalignment detection method for a vehicle is provided by: capturing images of a belt arranged on a plurality of pulleys of an accessory drive system via a plurality of digital cameras, wherein the belt includes a contrast element visible by the cameras; analyzing data indicative of the images to determine whether the contrast element is present in the captured images; and identifying the belt as misaligned when the contrast element is detected in at least one image.

[0074] According to one embodiment, the present invention is further characterized in that one or more of the multiple digital cameras are arranged to capture an image of the planar side of the belt at one or more of the multiple pulleys, wherein the belt has a ribbed side opposite to the planar side, and the ribbed side is in contact with the one or more pulleys.

[0075] According to one embodiment, the contrast element is a color feature detectable by the digital camera and is provided in or on the belt.

Claims

1. A method for detecting misalignment of a belt of a front-end accessory drive system, the method comprising: acquiring, via a plurality of optical sensors, a plurality of images of the belt disposed on a series of pulleys of the drive system, wherein the optical sensors are disposed external to the drive system and the belt includes a contrasting element detectable by the optical sensors and visually different from a color of the belt, the contrasting element having a color that changes based on a level of strain applied to the belt; analyzing, by a controller, data indicative of the acquired image to determine whether the contrast element is present in the captured image; as well as The belt is identified as being misaligned in response to the contrast element being in at least one of the acquired images.

2. The method of claim 1 , wherein the optical sensor is a digital camera, and the digital camera is arranged to capture images of different viewpoints of the belt at one or more pulleys of the drive system.

3. The method of claim 1 , further comprising: The drive system is brought to a standstill.

4. The method of claim 1, further comprising: A notification is generated and outputted in response to the belt being misaligned.

5. The method of claim 1 , further comprising: In response to determining that the contrast element is present in the acquired image, estimating a strain level of the belt, wherein the contrast element is based on a color characteristic of a change in an amount of strain applied to the belt due to the misalignment, and the strain level estimate is based on a color of the contrast element and pre-stored data correlating different colors with predefined strain levels.

6. The method of claim 5, wherein identifying the belt as misaligned further comprises: When the strain amount is greater than or equal to a strain threshold, the belt is determined to be misaligned.

7. The method of claim 1, wherein the contrasting element is provided as a color feature in or on the belt.

8. The method of any one of claims 1, 2, 3, 4, and 7, wherein acquiring the plurality of images further comprises: and causing a first optical sensor to capture a first image of a first pulley in the series of pulleys with the belt disposed on the first pulley to assess misalignment of the belt relative to the first pulley, wherein the first optical sensor is positioned to capture images of a rim of the first pulley and a first surface of the belt.

9. The method of claim 8, wherein analyzing the acquired image further comprises: A determination is made as to whether the contrast element is present in the first image, wherein the contrast element is disposed within the belt and is detectable by the first optical sensor when the belt is positioned on the rim.

10. The method of any one of claims 1, 2, 3, 4, and 7, wherein acquiring the plurality of images further comprises: A first optical sensor is caused to capture a first image of a front face of a first pulley to assess misalignment of the belt relative to a seat of the first pulley on which the belt is positioned.

11. The method of claim 10, wherein analyzing the acquired image further comprises: and determining whether the contrast element is present along an edge of the belt, wherein the contrast element is disposed along the edge of the belt and is detectable by the first optical sensor when the belt is positioned offset from the seat of the first pulley and is not detectable when the belt is aligned with the seat of the first pulley.

12. An alignment detection system for detecting misalignment of a belt mounted on a front end accessory drive system, the alignment detection system comprising: a plurality of digital cameras arranged to capture images of the belt disposed on a plurality of pulleys of the front end accessory drive system, wherein the digital cameras are configured to detect a contrasting element on the belt, the contrasting element being visible to the digital cameras and visually distinct from the belt, the contrasting element having a color that changes based on a level of strain applied to the belt; as well as a controller configured to process data indicative of the captured images to determine whether the belt is misaligned on the front end accessory drive system, wherein the controller determines that the belt is misaligned in response to the contrast element being captured in one or more images and determines that the belt is aligned in response to the contrast element not being present in the captured images.

13. The system of claim 12, wherein: One or more of the plurality of digital cameras are arranged to capture images of a front face of one or more of the plurality of pulleys of the front end accessory drive system to detect misalignment of the belt relative to the one or more pulleys, and The controller is configured to determine that the belt is misaligned in response to detecting the contrast element along an edge of the belt in at least one image captured by the one or more digital cameras.

14. The system of claim 12 or 13, wherein one or more of the plurality of digital cameras are arranged to capture images of a rim of one or more of the plurality of pulleys and a first surface of the belt arranged on the one or more pulleys, wherein the first surface is opposite to a second surface of the belt and the second surface is in contact with a surface of a corresponding pulley of the one or more pulleys.

15. The system of claim 14, wherein the controller is configured to determine that the belt is misaligned in response to detecting the contrast element at the first surface of the belt in at least one image captured by the one or more digital cameras.

Images