Sensor unit with rollable adjustment housing and method of assembling same

Abstract

The present disclosure relates to a sensor unit having a rollable adjustment housing and a method of assembling the same, and more particularly, to a sensor (e.g., an automotive camera) unit and a method of assembling the same, including relative roll adjustment between components. The sensor portion (10) and the mounting portion (18) having a reference feature (19) engage at respective mating annular surfaces while the connector device (24) is aligned with and extends through an opening (26) in the mounting portion (18). The position of the mounting portion (18) relative to the sensor portion (10) can be selected by rotating the mounting portion or the sensor portion about the longitudinal axis (X-X) and then fixing it in place. The angular displacement may be limited by the size of the opening / slot (26). A connector cover (27) may be disposed coaxially with the connector (24), which connector cover also covers any gap in the slot (26).

Description

Technical Field

[0001] The invention relates to a sensor unit, in particular a camera housing for the automotive sector, and a method for implementing the sensor unit. Background Art

[0002] Sensors such as cameras are now common in automotive environments. The requirements for angular accuracy during assembly of automotive cameras are very high, i.e., aligning the surface features of the lens, imager, and housing on the PCB, as well as the connector location. Angular errors can be caused by surface mount technology (SMT) processes, component tolerances (e.g., imager chip, lens holder), and PCB layout. Summary of the invention

[0003] The present disclosure seeks to address the above-mentioned problems with conventional solutions and assembly methods, or at least provide an alternative to the public and suppliers / manufacturers of sensor devices.

[0004] According to a first aspect, a sensor unit may include, for example, a sensor subassembly (or sensor portion), a housing (or mounting subassembly / mounting portion) for attachment to the sensor subassembly (e.g., to enable subsequent mounting to a vehicle), and a connector device / port for connection to an external connector; wherein the housing portion is configured to be angularly displaceable relative to the sensor portion about a longitudinal axis. In a specific form, the sensor unit is a camera unit, and the subassembly includes a barrel housing a lens for fixing on a PCB at a distance from the imager. The mounting portion is a housing that is angularly adjustable relative to the barrel.

[0005] Specifically, the present disclosure relates to a sensor unit having: a sensor portion; a housing including one or more annular surfaces configured to engage with the sensor portion at a mating surface of the sensor portion; wherein, during assembly, a rotatable position is selectable to align or coincide with a reference feature of the housing (e.g., a terminal connection). The reference feature (as distinct from an external reference feature used to position the housing for operational use) may be an opening through the housing to receive a connector or a fixed connector integral with the housing. In this way, the housing / housing is manufactured to be rotatable relative to the sensor subassembly and / or a connection port electrically connected to the sensor / PCB during assembly.

[0006] The specific problem of roll control is solved by a specific design of the imager PCB, which has a shape that allows it to be actively aligned with the cylindrical lens. After aligning the imager / PCB, the subassembly is mounted into an annular support surface in the housing. The subassembly can be adjusted relative to the positioning features of the camera required for assembly into the vehicle and finally secured by welding or gluing. Angular positioning can be implemented / tested by using a fixture or a vision system to ensure correct assembly. Ultimately, the precise angular orientation of the camera results in the correct image display for operation in the vehicle.

[0007] The design may also allow the connector to be mounted in different positions. A few variants are possible, for example: where the connector is mounted in a cover / housing and the PCB is manufactured in a way that allows compensation of rolling movements and allows changing the position of the connector; or where the connector soldered to the PCB and cover has guides for rolling and position adjustment.

[0008] The assembly process to provide the required roll tolerance can be divided into two stages. In the first stage, the lens is actively aligned to the active area of ​​the imager PCB by using an adhesive. In the second stage, the combined lens and imager / PCB subassembly is mounted into a cylindrical seat, i.e. an annular bearing / contact flange, in the housing. The outer surface of the housing contains user reference features, which ultimately guide the sensor unit to the correct orientation position for installation in the vehicle. The customer reference features can be specific to the end use, i.e. the installation is a specific vehicle type or model.

[0009] As described above, during the insertion of the subassembly into the housing, the optical system can relatively locate the roll of the subassembly relative to the user reference feature. Once the correct angle / roll position is determined, the assembly is connected by welding or gluing.

[0010] In an embodiment, the sensor unit is provided with at least one connector element for assembly through an opening formed in the housing and mating with a connector position on the PCB. In this way, the assembled sensor unit comprises an external connector protruding from a side wall of the housing at a position selected according to customer requirements.

[0011] Obviously, the housing may be provided with multiple connector locations / connector elements to communicate with the PCB connection features if required by the operating unit.

[0012] Advantages of the proposed solution include reduced development time / tooling costs by separating common components, enabling more customer requirements to be met with one design. Notably, the full camera ASM achieves good accuracy of camera roll control relative to customer reference features during assembly.

[0013] A second aspect of the invention is achieved by a method of assembling a sensor unit, for example for providing a camera unit adaptable to a range of OEM vehicle requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Illustrative embodiments will now be described with reference to the accompanying drawings, in which:

[0015] Figure 1 The camera unit subassembly of the lens and imager PCB is shown;

[0016] Figure 2 An exploded overview of the complete camera unit assembly is shown;

[0017] Figure 3 Shown from Figure 2 An assembled view of the camera unit showing the roll adjustment possibility about the lens axis before connection;

[0018] Figure 4 shows an exploded bottom view of a camera assembly with a rear connector that allows compensation for minor tolerances in the roll alignment process (e.g., with a soldered connector on a PCB);

[0019] Figure 5 Shown from Figure 4 An assembly view of the camera unit;

[0020] Figure 6 shows an exploded bottom view of a camera assembly with a rear connector that allows for greater variation in roll adjustment about a desired position of the lens axis;

[0021] Figure 7 Shown from Figure 6 An assembly view of the camera unit;

[0022] Figure 8 shows an exploded bottom view of a camera assembly having a side mounted connector that allows for roll adjustment of the desired position about the lens axis;

[0023] Fig. 9 Shown from Figure 8 An assembly view of the camera unit;

[0024] Fig.10 An exploded bottom view of a camera assembly having a fixed side mounted connector is shown, enabling contact pads on a PCB to interface with the connector while allowing roll adjustment of the housing about the axis of the lens;

[0025] Fig.11An exploded bottom view of a camera assembly with a fixed side mounted connector is shown, enabling contact pads on a PCB to interface with the connector while allowing roll adjustment of the housing about the lens axis; and

[0026] Fig.12 An exploded bottom view of a camera assembly with a fixed side mounted connector is shown, enabling terminals on the PCB to connect with the connector while allowing roll adjustment of the housing about the lens axis. DETAILED DESCRIPTION

[0027] The following description provides exemplary embodiments and is accompanied by Figure 1 The invention is intended to explain the principles of the invention. However, the scope of the invention is not intended to be limited to the precise details of the embodiments or to the precise conformity of all system features and / or method steps, as variations will be obvious to those skilled in the art and are considered to be covered by the specification. The terms used herein for components should be given a broad interpretation, which also includes equivalent functions and features.

[0028] In some cases, several alternative terms (synonyms) for structural and system features have been provided, but these terms are not intended to be exhaustive. For the avoidance of doubt, any term separated by the " / " symbol generally refers to an alternative "or" expression in which the term can be used interchangeably. Descriptive terms should also be given the broadest interpretation; for example, the term "comprising" used in this specification means "at least partially composed of...", so that each statement including the term "comprising" in this specification is interpreted, and features other than the features at the beginning of the term may also exist. Related terms such as "include" and "include" are interpreted in the same way. Any directional terms, such as "vertical", "horizontal", "upper", "lower", "lateral", "upper" and "lower", are used for ease of explanation, usually with reference to the form shown in the figure, and if equivalent functions can be achieved with alternative sizes and / or directions, it is not intended to be ultimately limited. All directional terms are related to each other.

[0029] The description herein relates to embodiments with a specific combination of steps or features, however, it is contemplated that further combinations and cross-combinations of compatible steps or features between the embodiments will also be possible. In fact, separate features can function as the present invention independently of other features, and are not necessarily required to be implemented as a complete combination.

[0030] It should be understood that the illustrated embodiments show applications for illustrative purposes only. In fact, the present invention can be applied to many different configurations, where the embodiments are straightforward to implement for those skilled in the art.

[0031] Figure 1The sensor portion is shown, i.e. a subassembly 10, comprising a barrel 11, a lens 12 and a base 13 concentric with the barrel 11, the base 13 having an interface surface for receiving a printed circuit board PCB 14. The PCB 14 in turn supports an imager device 15 facing the lens 12. Thus, the illustrated embodiment relates to a camera / image sensor.

[0032] In practice, the PCB / imager 15 is positioned relative to the lens 15 and fixed in place at an optimal focus by the adhesive 16. The component information may be provided as text indicated by the surface marking 17 or as a readable code.

[0033] Figure 2 The installation portion 18 is shown introduced into Figure 1 The assembled sensor portion 10 is shown.

[0034] The mounting portion 18 may include a wall housing that provides a cavity to accommodate any protruding parts from the subassembly 10 (e.g., the electronic components of the PCB 14, on the opposite side of the imager 15). Externally, the housing 18 may include one or more surface structures 19 that serve as position reference features for use when the assembled sensor unit is installed, for example, in a vehicle. There may be one or more reference features.

[0035] The housing 18 is formed as a cup-shaped or cylindrical housing for accommodating a PCB and / or other components. The closed end 20 has an upright peripheral sidewall to form a cup shape and create an internal cavity, further defining an edge / open end 21 adapted to engage with an annular surface of the sensor base 13. The opening 21 may engage with the base 13 of the sensor subassembly by any suitable feature, such as one or more annular surfaces or flanges / bearing surfaces that enable interference or a looser fit / contact to allow relatively free rotational movement during assembly.

[0036] Figure 2 Also shown is a connector device or cover 22, such as a smaller cylindrical wall, upstanding from the closed end 20. Finally, an external connector (not shown) can be inserted into or otherwise connected to the connector 22 to provide electrical communication (e.g., power and / or data) to the terminals on the surface of the PCB 14.

[0037] like Figure 3 As shown, when initially assembled, the subassemblies of sensor 10 and housing 18 are able to move relative to each other about a longitudinal axis XX through barrel 12. Torsion direction arrows 23 indicate the relative freedom of movement of the components about the roll axis (ie, XX).

[0038] In this way, the reference / registration features 19 can be rotationally adjusted relative to the lens barrel and associated image forming assembly. Once in the desired orientation, i.e., the orientation determined by the monitoring system or fixture, the assembly can be fixed in place by appropriate means, i.e., adhesive or welding.

[0039] Figure 4 and Figure 5 Shown from Figure 3 1 and 12 , and in particular, a sub-connector 24 soldered to the PCB 14 (hidden within the housing 18) extends through a small opening 25 formed through the closed end 20. The opening 25 serves as a reference feature for alignment with the sensor portion. The opening 25 can be wide enough to allow some angular adjustment (i.e., rotation in direction 23) in the placement of the housing 18 relative to the base 12. The connector cover element 22 can then be arranged coaxially with the sub-connector 24 and glued / welded to the appropriate position on the surface 20, thereby covering the opening 25. If the opening 25 is not completely coaxial with the connector 24, any variation will be hidden by the cover 22, as shown in FIG. Figure 5 shown.

[0040] In order to allow for a greater variation in the permissible angular rotation of the relative components 10 and 18 during assembly, Figure 6 and Figure 7 A second embodiment is shown. Specifically, an elongated opening or arcuate slot (arc centered on axis XX) 26 is formed through closed end 20 and serves as a reference feature for aligning with / accommodating protruding sub-connector 24, fixedly connected (e.g., by welding) to internal PCB 14, and thus rotationally fixed with lens barrel 11 as a whole.

[0041] In this way, the relative rotation of the housing 18 can be Figure 4 The relative rotation is greater. Figure 4 The connector cover element 27 is defined by the distal end of the slot 26 when it engages against the side wall of the sub-connector 24. Once the desired rotational position is determined, the connector cover element 27 can be coaxially placed on the sub-connector 24 and in a manner similar to the sub-connector 24. Figure 5 28 to provide sufficient surface area to cover and conceal the groove 26 (see Figure 7 ). In the form shown, the flange 28 is of corresponding arc shape to match the groove 26, although it should be a larger portion of a circle so that it can cover the end of the groove 26. Other structures are also possible, as long as the groove 26 is preferably covered.

[0042] Figure 7An assembled view is shown with all parts glued or welded together, i.e. housing 18 has been rotationally adjusted, secured and connector cover 27 in place / adhered to closed end 20. When the unit is mounted for its final use, connection terminals 24 are visible for an external connector to be plugged therein.

[0043] Figure 8 and Fig. 9 Shown with Figure 6 and Figure 7 Functionally similar concept except that the sub-connector means 24 is offset 90 degrees, i.e. extends transversely through a slot 29 formed in the cylindrical side wall of the housing 18. The slot 29 is letterbox shaped through the cylindrical wall and can be covered by a complementary shaped flange 30 at the base of the connector cover element 27 during assembly.

[0044] Also can see the engagement feature 31 at the side wall of connector cover 27, it is used with the mating part of external connector (not shown) butt joint.In the form shown, it is hook-shaped, in use, it can be captured and released by the elastic mating part.

[0045] and Figure 6 and Figure 7 Same situation, Figure 8 and Fig. 9 The embodiment allows limited rotational adjustment of the mounting portion 18 and its reference feature 19, which is determined by the length of the slot 29 before it can be angularly secured in place and accomplished by the engagement and securing of the cover 27 / flange 30 over the exposed slot. The connector terminals 24 are accessible within the connector cover 27 for connection to an external connector (not shown).

[0046] Fig.10 , Fig.11 and Fig.12 Variations are shown that are generally applicable to rear or side (as shown) extension connectors 24. That is, contact with PCB terminals can be maintained on arc pads 32, multi-part arc pads 33, or contact points 34 arranged in an arc. All arcs are centered on the rotation axis of the housing 18, i.e., the roll axis XX.

[0047] Obviously, Figures 10 to 12The construction allows the housing 18 to have a fixed / molded location for a protruding connector 24 which is a reference feature for alignment with the sensor portion which may or may not have a cover 27 and which may extend from a surface of the closed end 20 rather than a side wall. As the connector 24 is rotated angularly about the axis XX with respect to the housing 18 and its fixed external reference feature 19, electrical contact is maintained between the PCB 14 connector 24 via the contact pads / terminals over the range of motion as provided by the arcs 32, 33 and 34. In this way, the relative rotation of the housing can be adjusted and then fixed in place.

[0048] exist Fig.10 In the form shown, continuous contact is maintained over the angular adjustment movement between the two extremes. Fig.11 and Fig.12 , contact is achieved only at certain positions (e.g., three positions as shown) that can correspond to specific model requirements.

[0049] A variation of the foregoing may be to feature internal flexible wires between the connector 24 and the terminals of the PCB. That is, the wires are of sufficient length to accommodate rotational adjustment of the housing 18 relative to the fixed sensor portion 10 in either direction 23. Such an arrangement is functional but requires additional pre-installation (e.g., connector-to-connector soldering) compared to the contact arrangement shown.

[0050] As with all embodiments, the angle adjustment can be set and fixed according to its end use through appropriate monitoring and labeling of the parts.

[0051] The common concept of all embodiments is to enable fine angular adjustment of the imager in front of a reference feature and then fix the relative position. Thus, in contrast to the prior art where automotive camera models are only configured for one angular connector orientation (needing to develop new components if other connector orientations are required), the present camera unit is ready to accommodate multiple connector orientation variants (e.g. German standards FAKRA, Fachkreis Automobil) and does not require a new housing configuration for each possibility, only customization during assembly.

[0052] The exemplary embodiments herein relate to, for example, a camera unit having a lens and an imager, but other sensor types may also benefit from an adaptable housing (e.g., a subassembly) that may be configured according to the direction of entry of a connector that will need to interface with it when assembled into a vehicle or similar assembly. Thus, the invention more generally relates to a two-part sensor unit / housing, i.e., housing associated electronics with or without the sensor itself.

[0053] As a further summary, a sensor (e.g., automotive camera) unit and method of assembling the same are described herein, including relative roll adjustment between the components. A sensor portion and a mounting portion having reference features engage at corresponding mating annular surfaces, with a connector device aligned with the mounting portion and extending through the mounting portion. The position of the mounting portion relative to the sensor portion can be selected by rotating the mounting portion or the sensor portion about a longitudinal axis and then securing it in position. Angular displacement can be limited by the size of the opening / slot. A connector cover can be arranged coaxially with the connector and also cover any gaps in the slot.

Claims

1. A sensor unit, comprising: Sensor Department; a housing including one or more annular surfaces configured to engage the sensor portion at a peripheral mating annular surface of the sensor portion; Wherein, during the assembly process, the relative rotatable position of the housing and the sensor portion is selectable so as to align the sensor portion with a reference feature of the housing.

2. The sensor unit according to claim 1, further comprising: A connector device is configured to extend through the wall of the housing so as to be in electrical communication with the terminal portion of the sensor part at one end and to be compatible with an external connector at another end.

3. The sensor unit according to claim 2, wherein: The reference feature is an opening formed through a closed end or side wall of the housing, the opening being configured to receive the connector device therethrough.

4. The sensor unit according to claim 3, wherein: The opening is elongated and arcuate and is configured to limit rotational movement of the connector device extending therethrough.

5. The sensor unit according to claim 3 or 4, comprising a connector cover for closing the connector device and covering the opening.

6. The sensor unit according to claim 2, wherein: The connector arrangement is formed in a fixed position relative to the housing and includes a reference feature alignable with the sensor portion.

7. The sensor unit according to claim 6, wherein: The terminal portion comprises a contact configured to maintain an electrical connection with a reference feature of the connector arrangement when a rotatable position of the housing relative to the sensor unit is selected.

8. The sensor unit according to claim 7, wherein: The contacts are arranged in an arcuate path.

9. The sensor unit according to claim 1, wherein: The sensor unit includes a lens and an imager.

10. The sensor unit according to claim 1, wherein: The sensor portion and the housing are glued or welded together to fix the selected rotational position.

11. A method of assembling a sensor unit according to any one of claims 1 to 10, the method comprising the following steps: engaging respective mating surfaces of the sensor portion and the housing; selecting a position of the housing relative to the sensor portion by rotating the housing or the sensor portion, thereby aligning a reference feature with the sensor portion; as well as The selected position is fixed by bonding the sensor portion to the housing.

12. A method according to claim 11, when dependent on claim 5, comprising the steps of: The connector cover is coaxially engaged with the connector device to cover the opening, and the connector cover is coupled to the housing.

13. A method according to claim 10, when dependent on claim 7, wherein: Prior to engaging the mating surfaces, the terminal portions of the sensor portion are aligned with the connector device such that electrical engagement is achieved when the sensor portion and mating portion are in contact.

14. The method according to claim 11, wherein: Alignment with the reference features and selection of the rotatable position of the housing is aided by a jig or a vision inspection system.

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