Manufacture of a device for environmental detection for a motor vehicle

Abstract

The invention relates to a device for environmental detection of a motor vehicle, comprising a laser detection device for detecting the environment of the motor vehicle, a holder fixedly connected to the detection device, the holder being designed to position the detection device on the body of the motor vehicle, and a cover element, wherein the holder and the cover element each have an end face which faces the end face of the other. Furthermore, the invention relates to a method for producing an environmental detection device by means of laser transmission welding.

Description

Technical Field

[0001] This invention relates to an apparatus for environmental testing of motor vehicles and a method for manufacturing such an apparatus. Background Technology

[0002] Especially for autonomous driving functions, motor vehicles require laser detection devices, such as LiDAR sensors. These laser detection devices are typically located at the front of the vehicle, for example, behind the front fender.

[0003] In modern vehicles, due to the high demand for avoiding optical distortion in the field of view of environmental detection, either the area of ​​the LIDAR field of view is cut out from the covered outer casing, or the environmental detection unit is configured so that its field of view is not obstructed by the outer casing.

[0004] However, due to the open arrangement of the environmental detection unit and, in particular, the LIDAR sensors, the overall visual appearance of the vehicle may be obstructed. It is desirable that the environmental detection unit be positioned behind the outer casing component so that the visual appearance of the vehicle is not hindered.

[0005] However, the functionality of environmental monitoring equipment, such as those based on LiDAR, should not be impaired in terms of lifespan. Particular attention should be paid to correcting optical distortion, which must not exceed a tolerance of 0.1°. To achieve this using LiDAR, it should be directly and securely bonded to the outer casing component. Summary of the Invention

[0006] In this context, the objective of the present invention is to improve a method for manufacturing an environmental testing device for motor vehicles and an environmental testing device for motor vehicles.

[0007] The task is accomplished by an environmental testing device for motor vehicles according to the invention and a method for manufacturing the environmental testing device according to the invention.

[0008] According to one aspect, a device for environmental detection of motor vehicles, particularly for monitoring distance and speed, is provided. The device comprises at least:

[0009] (a) Laser detection devices, particularly including laser emitters and detection sensor devices, such as LIDAR units. LIDAR units commonly used in modern motor vehicles have an infrared wavelength of about 905 nanometers (other wavelengths are naturally conceivable, which are considered for eye protection and required functionality) and a pulse length of several nanoseconds (currently about 2 ns).

[0010] (b) A bracket fixedly connected to the detection device, the bracket being particularly made of or composed of a plastic material such as ABS or PC, the bracket being configured to mount the detection device (with as little relative clearance as possible) onto the body of a motor vehicle.

[0011] (c) In particular, an outer casing member fixedly connected to the bracket, such as a front fender or other trim piece (e.g., a badge trim piece bearing the vehicle manufacturer's emblem), is completely or at least permeable to the wavelength of the laser and / or to laser radiation of any wavelength in the detection area (i.e., in the area where the detection area intersects with the outer casing member). The outer casing member may also be a closed cooling grille surface, i.e., the surface between the headlights of the motor vehicle. The outer casing member may be a part constituting part of the vehicle body, such as a body cover, particularly a front cover, a rear cover; or a side door, fender, side sill guard, or window glass. The outer casing member preferably covers an area significantly larger than the projected area of ​​the bracket or laser detection device projected onto the outer casing member. For example, the outer casing member is at least two, three, four, five, six, seven, eight, or ten times larger than the external dimensions of the bracket or laser detection device.

[0012] Here, the support and the outer cover component each have one end face facing the other end face, wherein the outer cover component is opaque, i.e., not transparent, particularly in the visible wave region.

[0013] The bracket and the outer cover are fixedly connected to each other at a distance from the detection area on their respective facing end faces, and in particular, cannot be disassembled without damage.

[0014] This allows the bracket and the outer casing to reliably maintain their relative positions and thus their optical relationship with respect to the laser throughout the lifespan of the vehicle.

[0015] The support, in particular, comprises or is made of a material that is not permeable by a laser but can be melted by a laser, especially a plastic material, or has such a material at least in the region of its end face.

[0016] Currently, the detection area should be understood in particular as an area through which laser radiation used for laser detection is emitted to the environment by the laser passing through the area, or which can be propagated from the environment through the area to the detection sensor of the device. Typically, the detection area has a cone or frustoconical shape, originating from the laser emitter.

[0017] Currently, the detection window can be referred to as any intersecting plane (Schnittebene) between the detection area and the components of the environmental detection equipment.

[0018] The laser detection device preferably has a particularly enclosed or substantially enclosed housing. Advantageously, the housing is mounted on a bracket. In particular, the laser detection device is mounted solely on the bracket, thereby defining the position of the laser detection device solely by the bracket, wherein the position of the bracket is in turn defined by a non-removable connection to the outer casing member.

[0019] The housing of the laser detection device may advantageously have protective glass that is permeable to the wavelength of the laser.

[0020] Typically, the laser detection device is an optoelectronic component, which is a supplier component for vehicle manufacturers. The vehicle manufacturers obtain the supplier component as a component and then integrate it into the vehicle, which is done according to the invention by fastening it to a bracket.

[0021] Advantageously, the bracket is connected to the vehicle only via an outer casing component.

[0022] Therefore, only the outer casing component determines the position of the bracket and thus the laser detection device.

[0023] The bracket can be configured as a single piece.

[0024] The support advantageously has a closed periphery with a corresponding end face, which is also closed, i.e., annular, wherein annularity includes not only circular rings, but also any kind of closed ring, such as rectangular rings or other polygonal rings or elliptical rings.

[0025] Therefore, the connection can be made completely and continuously sealed between the outer casing component and the support, so that no contaminants or liquids, such as water, will intrude between the outer casing component and the support.

[0026] The bracket can completely, that is, surround the housing of the laser detection device in all directions parallel to the outer casing member, thereby correspondingly determining the position of the laser detection device.

[0027] According to another aspect, a method for manufacturing an environmental monitoring device (das) is provided, the environmental monitoring device being constructed in particular according to an embodiment of the present invention, the method comprising the following steps:

[0028] (1) Position the end face of the outer cover component and the end face of the bracket relative to each other.

[0029] (2) The end faces are welded together by means of at least one laser beam, wherein the at least one laser beam is guided through the outer casing member for welding.

[0030] This specifically means that the connection between the support and the outer casing is introduced by means of laser radiation guided through the laser-transparent outer casing, which is specifically designed to melt the material of the support at its end face and, if necessary (where robustness of the connection is required), also melt the material of the outer casing at its end face.

[0031] The present invention is further based on the consideration that the outer casing and the support itself can be connected very reliably in a very simple way by means of plastic welding, which was previously not technically economical or initially meaningless because the arrangement of the detection device and the outer casing was not technically economical or initially meaningless, since the guidance of the laser beam toward the potential connection point was blocked by the outer casing to be installed.

[0032] The present invention is based on the idea that a detection device having a LIDAR transmitter and sensor is securely joined to a laser-transmitting beam welded (also known as laser transmission welding) using a bracket. Here, the outer casing is made of a material that is transparent to LIDAR or laser, but opaque in the visible wavelength range, for example, appearing black or gray. Due to this characteristic, in the case of laser transmission beam welding, the outer casing emits a laser beam after it has been penetrated by the laser beam. The material of the bracket to which the LIDAR transmitter and sensor are joined absorbs the laser, at least the wavelength used.

[0033] This ensures a material locking connection between the outer casing components and the support of the testing device.

[0034] Here, the outer casing component, according to one embodiment, has at least one protective coating, particularly for laser-transparent protective paint, which at least protects the outer casing component from environmental influences.

[0035] By connecting the bracket to the outer casing components, as well as to the LIDAR transmitter and sensors, relative movement between the connected components is eliminated.

[0036] In one embodiment, the connection on the end face is formed at a distance from the outer shell profile of the bracket in the radial direction (particularly with respect to the longitudinal axis of the bracket). Here, the outer shell profile should be understood in particular as the entire outer shell surface or side surface of the bracket, regardless of whether the bracket is rotationally symmetrical or prismatic on the outer shell surface.

[0037] Even when welding through the outer casing components, this ensures that the joints or connection points remain reliably consistent, unlike welding, for example, on the edges of the outer casing and the end faces of the bracket, where additional dimensional tolerances of the bracket's external dimensions must be considered to achieve consistent weld or weld point quality.

[0038] In one embodiment, the connection is formed on the corresponding end face in the bracket and / or housing component by means of at least one molten area, particularly by means of one or more plastic weld points and / or welds.

[0039] The material-locked connection ensures reliable dimensional accuracy and / or a low failure rate throughout the lifespan of the vehicle and under certain high-frequency alternating loads.

[0040] In one embodiment, the connection is formed to completely surround the detection window on each end face, the detection window being defined in particular by the intersecting plane of the end face and the detection area.

[0041] This enables the laser detection area to be sealed in the space between the support and the outer casing, especially relative to optically influential environmental factors such as moisture and / or dirt.

[0042] In one embodiment, the end faces of the bracket and the outer cover are formed complementaryly to each other.

[0043] Therefore, it can also be referred to as a common end face of the support and the outer casing. If this end face is bent, for example, due to the bending of the outer casing, the intersecting plane of the end faces should be understood as the corresponding bent surface.

[0044] This configuration also minimizes the probability that optically active environmental influences, such as moisture and / or dirt, may be detected in the detection area.

[0045] In one embodiment, the outer cover member (in particular) is configured to be permeable to laser radiation, particularly in the projection area that is vertically projected onto the end face of the support and into the outer cover member.

[0046] Thus, the outer casing is constructed such that laser radiation intended for connection with the support can be guided through the outer casing without altering its material structure, as there is no (significant) heat input.

[0047] In one embodiment, the heat input is achieved by superimposing two or more laser beams guided through the outer casing member, particularly superimposing them on or near an intersecting plane in the support.

[0048] By superimposing multiple laser beams, the laser transparency requirement for the outer casing component can be set lower because less heat power is directed through the outer casing component at any location within it (compared to a welded connection performed by a single laser beam).

[0049] In one embodiment, the incident point of the laser beam on the end face of the support and / or the focal point of the superimposed laser beams move over time to achieve a linear weld. Attached Figure Description

[0050] Other advantages and applications of the invention will become apparent from the following description in conjunction with the accompanying drawings.

[0051] Figure 1 A sectional side view shows an apparatus for environmental monitoring according to an exemplary embodiment of the invention.

[0052] Figure 2 From the front along Figure 1 The sectional view with section line AA drawn in the middle shows Figure 1 The equipment in the middle.

[0053] Figure 3 Showing the manufacturing process Figure 1 An exemplary first method for devices in [the context of this text].

[0054] Figure 4 Showing the manufacturing process Figure 1 Another exemplary method for devices in this context.

[0055] Figure 5 With the help of Figure 2 The sectional view shows Figure 3 The method steps of the exemplary method in the example are shown. Detailed Implementation

[0056] Figure 1 A device 1 is shown for environmental detection of motor vehicles (not shown otherwise), the device being specifically configured for spacing and speed monitoring.

[0057] Device 1 includes a laser detection device 2, which is configured as a LIDAR unit and includes a laser emitter 4 and a detection sensor 6. The detection sensor has a detection area 8, which specifically encompasses the emission area of ​​the laser emitter 4. The LIDAR unit preferably has a housing with a protective glass (not shown).

[0058] Furthermore, the device 1 has a bracket 10 fixedly connected to the detection device 2 (via a housing), the bracket being configured to mount the detection device 2 onto a vehicle body (not shown), such that the detection device 2 is fixedly mounted to the vehicle body without significant gaps. The bracket is made of a material that is not penetrated by a laser but can be melted by a laser, particularly a plastic material, or at least has such a material in areas of its end faces.

[0059] Device 1 also has an outer cover member 12 fixedly connected to the support 10, which in this embodiment is completely transparent to the wavelength of the laser 4. The outer cover member 12 is made particularly opaque, i.e., impermeable, in the visible wavelength range, so that the outer cover member appears black in this embodiment.

[0060] The Lidar unit is connected to the vehicle only via bracket 10, and is thus held solely by the outer casing member 12. The outer casing member 12 extends over a significantly larger area than the bracket 10, so that the location of the Lidar unit or the section of the outer casing member 12 used as the front end (Radom) of the Lidar unit is not visible from the outside.

[0061] In embodiments not shown, the outer cover member 12 may also be configured to be permeable to laser radiation of any wavelength and / or to be completely permeable to laser only in the detection area 8.

[0062] In each case, the bracket 10 has an annular end face 11, and the outer cover member 12 has an end face 13. The two end faces 11 and 13 face each other and are configured to be congruent, such that the two end faces abut against each other.

[0063] By means of the surrounding, closed ring-shaped plastic weld seam 14 (also see) Figure 2 The bracket 10 and the outer casing 12 are material-locked together on their facing end faces 11 and 13. In the embodiment, the weld 14 is radially spaced outward from the detection area 8 and radially inward from the outer shell profile 9 of the bracket 10 on the end faces 11 and 13.

[0064] In this way, the bracket 10 is fixedly and irremovably connected to the outer cover component 12 by a weld 14, which is completely contained within the interior of the plastic bodies of the bracket 10 and the outer cover component 12 that are in contact with each other.

[0065] The optimized positioning of the connection part can be achieved by means of... Figure 3 Alternatively, it may be implemented using the manufacturing method described in one of the embodiments of 4, wherein laser radiation for joining is applied to the connection portion through the outer casing member 12.

[0066] This allows the bracket and the outer casing to reliably maintain their relative positions and thus their optical relationship with respect to the laser (Leser) throughout the lifespan of the vehicle.

[0067] Weld 14 is formed on end faces 11 and 13, completely surrounding the inspection window 16, which is defined by the intersecting plane of the end faces and the inspection area 8. This seals the space between the support 10 and the outer casing 12 against moisture and contaminants.

[0068] exist Figure 2 In particular, it can be clearly seen in the cross-sectional view AA that the weld 14 has a distance (Beanstandung) that is radially outward from the inspection window 16 and radially inward from the outer shell profile 9 of the support 10.

[0069] exist Figure 3 An exemplary first method for manufacturing equipment 1 is shown in the figure.

[0070] As shown, the bracket 10 and the outer cover component 12 are positioned relative to each other with their abutting end faces 11 and 13.

[0071] The end faces 11 and 13 are welded together by means of a single laser beam 20 using a laser welding head 21.

[0072] For welding, the laser beam is guided through the outer casing member 12, where no heat generation occurs due to the laser-permeable configuration of the outer casing member 12. Heat generation only occurs when the laser beam 20 is incident on the end face 11 of the bracket 10. This is because the bracket 10 is not made of laser-permeable plastic.

[0073] The connection between the support 10 and the outer cover 12 is thus introduced through the laser-transparent outer cover 12 by means of the laser beam 20, in such a way that the material of the support 10 melts on its end face 11, and the material of the outer cover 12 also melts on its end face 13 by the heat input.

[0074] exist Figure 4 An exemplary second method for manufacturing equipment 1 is shown. This exemplary second method is consistent with... Figure 3 The difference shown is particularly that the heat input from the end face 11 to the support 10 is achieved by superimposing two laser beams 20.1 and 20.2, which are guided separately through the outer casing component.

[0075] By superimposing the two laser beams 20.1 and 20.2 (originating from welding heads 21 and 22), the heat input can be precisely limited in position to the overlapping portion of the two beams 20 and 21.2.

[0076] exist Figure 5 China is targeting according to Figure 3 An exemplary first method is shown, Figure 2 How is the surrounding weld 14 gradually introduced through the movement or pivoting of the weld head 21? It goes without saying that, according to... Figure 4 A similar operation is also specified in the second example method, in which welding heads 21 and 22 are pivoted or moved such that the superposition point of the two laser beams 20.1 and 20.2 moves accordingly.

[0077] List of reference numerals

[0078] 1. Environmental monitoring equipment

[0079] 2. Laser Detection Device

[0080] 4. Laser emitter

[0081] 6. Detection sensor components

[0082] 8 Detection Area

[0083] 9. Outline of the bracket's outer shell

[0084] 10 supports

[0085] 11. End side of the bracket

[0086] 12. Outer casing components

[0087] 13. End side of outer casing component

[0088] 14 Plastic welds

[0089] 16 Detection Window

[0090] 20 laser beams

[0091] 21, 22 Laser welding heads

Claims

1. An apparatus (1) for environmental testing of motor vehicles, the apparatus comprising: - A laser detection device (2), which has a laser emitter (4) and a detection sensor (6), the detection sensor having a detection area (8) that completely encompasses the emission area of ​​the laser emitter (4). - A bracket (10) fixedly connected to the laser detection device (2), the bracket being configured to mount the laser detection device onto the body of a motor vehicle. - An outer cover component (12), which is permeable to laser radiation of any wavelength at least in the region projected onto the end face of the support and is made of a material that is opaque in the visible wavelength range, wherein the support and the outer cover component each have an end face (11, 13) facing the other end face (13, 11). Its features are, The bracket and the outer cover are fixedly connected to each other on their facing end faces by means of at least one laser beam (20; 20.1, 20.2), the connection being formed on each end face completely surrounding the detection window (16), the detection window being defined by the intersecting plane of each end face (11, 13) and the detection area (8), the laser detection device (2) being fastened to the motor vehicle only by the bracket, so that the laser detection device (2) is held only by the outer cover (12), the outer cover being an integral part of the motor vehicle body.

2. The device according to claim 1, characterized in that, The outer casing is completely permeable to laser radiation of any wavelength.

3. The device according to claim 1, characterized in that, The connection is formed on the end face at a distance from the outer shell profile (9) of the bracket in the radial direction.

4. The device according to any one of claims 1 to 3, characterized in that, The connection is formed in the bracket and / or the outer casing member on the respective end face by means of at least one melted area.

5. The device according to claim 4, characterized in that, The connection is formed on the respective end face in the bracket and / or the outer casing member by means of one or more plastic weld points and / or welds.

6. The device according to any one of claims 1 to 3, characterized in that, The end faces of the bracket and the outer cover are formed complementaryly to each other.

7. The device according to any one of claims 1 to 3, characterized in that, The laser detection device (2) has a housing, and the housing is mounted on a bracket (10).

8. The device according to claim 7, characterized in that, The shell is a closed shell.

9. The device according to any one of claims 1 to 3, characterized in that, The bracket (10) is connected to the motor vehicle only through the outer cover component.

10. A method for manufacturing an environmental monitoring device (1), said environmental monitoring device being constructed according to any one of claims 1 to 9, said method comprising the following steps: - Position the end face (13) of the outer cover component (12) and the end face (11) of the bracket (10) relative to each other. - The end faces are welded together using at least one laser beam (20; 20.1, 20.2). Its features are, In order to weld the at least one laser beam through the outer casing member (12), the weld (14) is formed on the end faces (11, 13) completely surrounding the detection window (16), the detection window being defined by the intersecting plane of the end faces and the detection area (8), the laser detection device (2) being fastened to the vehicle only by a bracket, so that the laser detection device (2) is held only by the outer casing member (12), the outer casing member being an integral part of the vehicle body.

11. The method according to claim 10, characterized in that, Heat input is achieved by superimposing two or more laser beams (20.1, 20.2) guided through the outer casing components.

12. The method according to claim 11, characterized in that, The overlapping is performed in or near the intersecting planes of the support.

13. The method according to any one of claims 10 to 12, characterized in that, The incident point of the laser beam on the end face of the support and / or the focal point of the superimposed laser beams move over time.

14. The method according to any one of claims 10 to 12, characterized in that... The following steps are performed: The housing of the laser detection device (2) is assembled onto the bracket (10).

15. The method according to any one of claims 10 to 12, characterized in that... The following steps are performed: The closed housing of the laser detection device (2) is assembled onto the bracket (10).

16. The method according to any one of claims 10 to 12, characterized in that, The bracket (10) is connected to the motor vehicle only through the outer cover component.

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