Harsh environment sensor housing and cleaning system

Abstract

A harsh environment sensor housing and cleaning system includes a sensor housing having a rotationally symmetric lens that can be cleaned in a lens cleaning space defined by the sensor housing. Each sensor housing includes a motor coupled to the lens to rotate the lens within the sensor housing, moving a soiled portion of the lens through the lens cleaning space for cleaning, and placing a clean portion of the lens in front of the sensor or camera within the sensor housing. The sensor housing and cleaning system includes a control unit, a fluid control valve, a manifold, and a fluid conduit to deliver a purge flow to each sensor housing. The fluid control valve has a reduced component count and can be used to control the flow of liquid or gas, such as air.

Description

Technical Field

[0001] The present disclosure relates to a system for protecting and cleaning cameras and sensors on motor vehicles operating in harsh environments. Background Art

[0002] Modern vehicles include an increasing number of cameras and sensors that provide critical information to vehicle operators and vehicle systems. Operator information can include real-time images of areas around the vehicle that are not visible to the operator (e.g., areas behind the vehicle). Operator information can also include signals regarding obstacles or other vehicles within or approaching one or more blind spots around the vehicle. Vehicle system information can be provided by sensors configured to detect obstacles, lane markings, pedestrians, or other vehicles to allow vehicle systems to perform functions such as automatic navigation, lane keeping, speed control, and emergency braking. Sensors include lidar (LIDAR) and other types of obstacle and motion detection sensors. Cameras can be arranged to provide images of the rear of the vehicle and the vehicle's blind spots.

[0003] Vehicles are exposed to a variety of environmental conditions, including snow and ice, dust, mud, road salt residue, and insects, which can form deposits on the external optical surfaces of cameras or sensors and reduce or prevent the cameras or sensors from performing their intended functions. Vehicles operate in a variety of environments, and the disclosed sensor systems are applicable to agricultural equipment, off-road construction equipment, highway transport and towing equipment, public transportation vehicles (e.g., buses and coaches), sport utility vehicles, campers, etc. Many of these vehicles operate at least part of the time in harsh environments, and the harsh environments may form deposits on the outermost surfaces of cameras and sensors, which must be removed for the cameras or sensors to function properly. In some cases, inoperative cameras or sensors can impede vehicle operation and cause the vehicle to be shut down until the cameras or sensors are cleaned. In some cases, cameras or sensors are placed in locations that may be difficult or inconvenient for operators or after-sales personnel to access.

[0004] Known camera and sensor cleaning systems are an extension of prior art window cleaning systems and use window cleaning fluid sprayed on the outer surface of the camera or sensor to remove deposits. Prior art systems have several drawbacks. The system tends to lack any physical wiping or other form of contact with the surface being cleaned, which makes the prior art system less effective in removing films or dried deposits such as bug residue or dried mud. The prior art system does not recycle the cleaning fluid. In cold environments, the window cleaning fluid necessarily contains a large amount of alcohol (such as ethanol and / or methanol), which is a hydrocarbon that causes air pollution and global warming when released into the environment. Failure to recycle the cleaning stream can also result in vehicle downtime if the cleaning stream reserve is depleted and the cleaning system thus cannot operate.

[0005] There is a need for a camera and sensor cleaning system for use on all types of vehicles that can effectively remove deposits formed on the camera and sensor.

[0006] There is a need for a camera and sensor cleaning system for use on vehicles that recycles the cleaning fluid to prevent the uncontrolled release of the cleaning fluid into the environment. Summary of the Invention

[0007] A harsh environment sensor housing and cleaning system includes a sensor housing having a rotationally symmetric lens that can be cleaned in a lens cleaning space defined by the sensor housing. The cleaning stream is recycled from each lens cleaning space for reuse or proper disposal. Each sensor housing includes a motor coupled to the lens to rotate the lens within the sensor housing, moving the dirty portion of the lens through the lens cleaning space for cleaning and positioning the clean portion of the lens in front of a sensor or camera within the sensor housing. Wipers and seals separate the lens cleaning space from the surrounding environment and from the sensor chamber in which the camera or sensor is mounted. Each sensor housing includes an outlet to discharge the used cleaning stream from the lens cleaning space for collection. The rotationally symmetric lens can be selected from the group including cylindrical, flat circular, hemispherical, a portion of a sphere, and convex dome.

[0008] The cleaning system includes a cleaning stream source, a distribution manifold, and fluid conduits connecting the cleaning stream source to the distribution manifold and the distribution manifold to the sensor housing. The distribution manifold supports a plurality of solenoid-operated fluid control valves that control the delivery of the cleaning stream to each sensor housing. The cleaning system can collect the used cleaning stream for proper disposal or can include a filter with a pump to filter the used cleaning stream and return the filtered cleaning stream to a reservoir for reuse.

[0009] The control unit is connected to a vehicle system that utilizes information from a camera or sensors contained within a sensor housing. The vehicle system alerts the control unit that one or more lenses need to be cleaned, and the control unit operates a cleaning fluid pump and actuates a solenoid valve in a distribution manifold to deliver a cleaning flow to a lens cleaning space. The control unit also powers a motor within the sensor housing to rotate the lens, moving the dirty portion of the lens through the lens cleaning space where the cleaning flow and a wiper remove substances from the outer surface of the lens. The rotation of the lens is used to position a clean portion of the lens in front of the camera or sensor.

[0010] A simplified high-flow electromagnetic actuated fluid control valve is disclosed. The inlet of the electromagnetic operated valve serves as the magnetic pole of the solenoid valve and includes an integral inlet coupler. The outlet of the electromagnetic operated valve defines a valve seat and includes an integral outlet coupler. A non-magnetic tubular body connects the inlet to the outlet and surrounds the axial gap between the armature and the second end of the inlet. The non-magnetic tubular body guides the magnetic flux generated by the electromagnetic coil through the armature and the magnetic pole, while also serving to contain fluid within the valve and support the inlet and outlet in an axial position that defines the opening distance of a valve member connected to the armature. The fluid control valve may include a non-metallic damping element located between the armature and the magnetic pole to prevent direct contact between the armature and the magnetic pole, thereby reducing the noise generated during valve operation.

[0011] The distribution manifold houses the electromagnetic actuated fluid control valve, and the control unit actuates the valve as needed to distribute the cleaning flow to the sensor housing as required. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 Shows a representative sensor cleaning system in accordance with aspects of the present disclosure;

[0013] Figure 2 Is a front view of a sensor housing incorporating a cleaning system in accordance with aspects of the present disclosure;

[0014] Figure 3 Is Figure 2 A vertical cross-sectional view of the sensor housing and cleaning system shown taken along line 3-3;

[0015] Figure 4 Is Figure 2 A horizontal cross-sectional view of the sensor housing and cleaning system shown taken along line 4-4;

[0016] Figure 5 Is a perspective view of a first embodiment of an electromagnetic operated high-flow valve in accordance with aspects of the present disclosure;

[0017] Figure 6 Is Figure 5 A vertical cross-sectional view of the electromagnetic operated high-flow valve;

[0018] Figure 7 is a vertical cross-sectional view of a second embodiment of an electromagnetic-operated high-flow valve according to aspects of the present disclosure;

[0019] Figure 8 is a top perspective view of a first embodiment of a fluid distribution manifold incorporating three electromagnetic-operated high-flow valves according to aspects of the present disclosure;

[0020] Figure 9 is through Figure 8 a horizontal cross-sectional view of a fluid distribution manifold, in which an electromagnetic-operated high-flow valve is shown in perspective;

[0021] Figure 10 is a horizontal cross-sectional view of an alternative fluid distribution manifold incorporating Figure 7 three electromagnetic-operated high-flow valves;

[0022] Figure 11 and 12 are schematic views of an optional sensor housing according to aspects of the present disclosure;

[0023] Figure 13 is a schematic view of an alternative sensor cleaning system using compressed air according to aspects of the present disclosure; and

[0024] Figure 14 and Figure 15 are a side view and a top view, respectively, of a third embodiment of a sensor housing according to aspects of the present disclosure. Detailed Description

[0025] Figure 1A representative embodiment of a harsh environment sensor cleaning system 10 in accordance with aspects of the present disclosure is shown. The system 10 includes a control unit 12, a fluid distribution manifold 14, a plurality of sensor housings 16, a fluid recovery filter 18, and a reservoir 20 having a pump. Fluid conduits 22 are shown connecting the reservoir 20 to the distribution manifold 14. Fluid conduits 24 extend from the distribution manifold 14 to each sensor housing 16. Separate fluid conduits 26 connect the distribution manifold 14 to one or more windshield washer nozzles (not shown). Fluid return conduits 30 are connected to the outlets of each sensor housing 16 to return the used fluid to the recovery filter 18, where particles are removed from the fluid before the used fluid is returned to the reservoir 20. The recovery filter 18 may include a replaceable filter element 32 and a pump to draw the used wash stream from the return conduit 30. The used wash stream may be filtered and reused or accumulated in a separate reservoir (not shown) for later filtration or proper disposal. The control unit 12, the manifold 14, the reservoir / pump 20, and the recovery filter 18 may be located in the engine compartment or other convenient locations on the vehicle. The sensor housings 16 are located at various positions on the associated vehicle, which is determined by the type and function of the camera or sensor within the housing 16.

[0026] The control unit 12 is electrically connected to the distribution manifold 14, each sensor housing 16, the fluid reservoir / pump 20, and the vehicle power supply and other vehicle control and communication systems 34. The control unit 12 includes a processor and a memory or a microcontroller having inputs for communication and signals, and outputs for delivering vehicle power to the pump 20, valves in the distribution manifold 14, and motors 50 in each sensor housing 16. The control unit 12 may also provide power to the pump to draw the used wash stream from the return conduit 30. Delivering the wash stream to the housing 16 requires powering the pump 20 and opening one or more valves in the distribution manifold 14. The control unit 12 is also electrically connected to each housing 16 to provide power to the motor 50 within each housing, which will be described in more detail below. The vehicle system 34 may monitor the quality of sensor and / or image data returned from sensors and cameras distributed on the vehicle and provide a signal to the control unit 12 to clean one or more sensors. Optionally, sensor cleaning may be performed on a schedule. The structure and function of the control unit 12 are well known to those skilled in the art and will not be discussed in detail in this application.

[0027] Figures 2 to 4Shows a first embodiment of a sensor housing 16 according to aspects of the present disclosure. While a particular configuration of the sensor housing 16 is disclosed, the present invention is not limited to the disclosed housing configuration. The sensor housing 16 includes a lid 42, a body 44, and a base 46. The lid 42, the body 44, and the base 46 together define a housing 16 that encloses a camera or sensor 48. The lid 42 defines a space that may include a motor 50 with a gear reduction. A motor mounting plate 52 is disposed between the lid 42 and the body 44 and supports the motor 50 within the lid 42. The mounting plate 52 includes an opening for a shaft 54 of the motor 50 to extend toward a sensor chamber 56 defined within the body 44. The body 44 defines a sensor opening 58 that spans at least 90° of the circumference of the sensor housing 16. The sensor opening 58 is for the sensor or camera 48 to receive information (such as light) from the environment and / or transmit signals (such as laser or infrared light) and receive signals returned from the environment. The size and angular range of the sensor opening 58 can be configured for the structure and function of the camera or sensor 48 mounted in the housing 16. For example, the sensor opening 58 can span 180° or more of the circumference of the housing 16. Optionally, the sensor opening can be planar and can be closed by a flat lens 80a as shown in Figure 11 and 12 or a dome-shaped lens 80b as shown in Figure 14 and 15 . The lenses 80, 80a, 80b are rotationally symmetric and span the sensor opening 58.

[0028] The base 46 includes a boss 60 for fasteners to mount the base to a vehicle surface (not shown). The base 46 also includes a peripheral upright edge with a radially protruding boss 62 that will mate with a corresponding lower end of the body 44 with a mating boss 64. Fasteners extend through the bosses 62 and 64 to connect the base to the body 44. This method of fixing the components of the housing 16 to each other is an example, and other methods such as spin welding or adhesives can also be used. A base 66 occupies the central region of the base 46 and protrudes upward to support a sensor bracket 68 that mounts the camera or sensor 48. As shown in Figure 3 , an annular seal 76 is positioned within the upright lip of the base 46 and defines a gap 70 between the outer circumference of the base 66 and the inner circumference of the seal 76. The base 66 and the base 46 define an opening sealed by a gasket 72. As shown in Figure 3 , the opening and the gasket 72 provide a sealed path for conductors 74 from the sensor 48 to connect to a vehicle power supply, automation, and guidance system.

[0029] The lens mounting plate 78 spans across the upper end of the main body 44 below the motor mounting plate 52. The function of the lens mounting plate 78 is to support and rotate the cylindrical lens 80, which extends downward from the lens mounting plate 78 inside the main body 44 and into the gap 70 defined between the base 66 and the seal 76. The lens mounting plate 78 defines a downward-facing annular groove 82 that receives the upper end of the cylindrical lens 80, which is fixed in the annular groove 82 by an adhesive or other known method. The radial periphery of the lens mounting plate 78 defines a gland for the seal 84 that abuts against the inner surface of the upper end of the main body 44. The cylindrical lens 80 can be made of Pyrex or other transparent and durable materials such as glass or very hard-coated plastics. The cylindrical lens 80 spans across the sensor opening 58 and protects the sensor chamber 56 from the intrusion of environmental moisture and contaminants, so that the sensor 48 is protected from the environment while still having a clear and unobstructed view through the sensor opening 58. In the disclosed embodiment, the lens mounting plate 78 is coupled to the motor shaft 54 by a hub 86 and fasteners, but any attachment method that ensures a reliable connection between the motor shaft 54 and the lens mounting plate 78 is compatible with the disclosed sensor housing 16.

[0030] As Figure 4 Best shown, the disclosed sensor housing 16 includes a wiper 88 that contacts the outer surface of the cylindrical lens 80. In the disclosed embodiment, there are 4 wipers 88, with two wipers 88 arranged on one side of the lens 80 and two wipers 88 arranged on the opposite side of the lens 80. The wipers 88 extend vertically in the main body 44 from the bottom of the lens mounting plate 78 to the top surface of the seal 76 such that the wiping edges of the wipers 88 contact the outer surface of the lens 80. The wipers 88 can be made of any known durable material and are used to remove debris from the surface of the lens 80. The number and configuration of the wipers 88 are not limited to the shown wiper configuration, and the wipers 88 can have the same or different configurations required to perform the desired function. For example, the wipers 88 can take the form of a hard brush or a similar device to help remove dry substances from the outer surface of the lens 80. On one side of the sensor housing 16 opposite the sensor opening 58 and between the two sets of wipers 88, the sensor housing 16 defines a lens cleaning space 90. The wipers 88 are also used to contain the cleaning flow within the lens cleaning space 90 on the vertical sides of the cleaning space 90, while the seal 84 and the seal 76 contain the cleaning flow within the lens cleaning space 90 at the top and bottom of the lens cleaning space 90, respectively. The vertical edge 89 of the main body 44 that defines the vertical side of the sensor opening 58 is arranged close to the outer surface of the lens 80 and provides a scraping action to remove debris that may accumulate on the outer surface of the lens.

[0031] The cleaning fluid nozzle 92 is arranged to spray a cleaning fluid onto the surface of the lens 80 within the lens cleaning space 90. The nozzle 92 can have any selected configuration to preferably spray the cleaning fluid onto the outer surface of the lens 80 that covers the entire surface (vertical and horizontal) of the lens 80 located within the lens cleaning space 90. The nozzle 92 can have more than one injection hole to distribute the cleaning fluid over the surface of the lens 80. The nozzle 92 or nozzles can be selected to spray the cleaning fluid onto the lens 80 with sufficient force to assist in removing substances from the lens 80. The wiper 88 will also be used to physically remove substances and the cleaning fluid from the surface of the lens 80. The sensor housing 16 defines a cleaning fluid outlet 94 for allowing the used cleaning fluid to flow out of the lens cleaning space 90. When the cleaning fluid is being released, an increase in pressure within the lens cleaning space 90 may help to facilitate the used cleaning fluid flowing out of the lens cleaning space 90 with gravity and the negative pressure generated by a pump that may be associated with the recirculation filter 18 in the recirculation conduit 30. In Figure 1 In one embodiment of the system 10 shown, the used cleaning fluid flows from the outlet 94 through the recirculation conduit 30 to the recirculation filter 18, where the pump pushes the used cleaning fluid through the filter and recirculates the filtered cleaning fluid back to the cleaning reservoir 20. In an alternative embodiment, the used cleaning fluid is collected for later recycling or disposal in an environmentally friendly manner. One objective of the disclosed system is to collect most of the cleaning fluid for reuse or proper disposal compared to the uncontrolled release common in the prior art.

[0032] Another aspect of the present disclosure relates to a simple, low-cost, high-flow valve that can be used in one or more distribution manifolds 14 to distribute the cleaning fluid to the sensor housing 16 and existing window washer nozzles on a vehicle. Figures 5 to 7 An embodiment of an electromagnetic actuated fluid control valve 100 is shown that has a reduced component count and provides a high flow rate. A first embodiment of the fluid control valve 100 is shown in Figure 5 and Figure 6 . The fluid control valve 100 can be used with liquids such as window cleaning solution or with gases such as compressed air with a working pressure up to 20 bar. The fluid contact components of the valve 100 are stainless steel selected to be compatible with the cleaning fluid and moisture. The valve 100 can be configured with a barb outlet as shown in Figure 7 or an O-ring outlet fluid connector as shown in Figure 5 and 6 . The electrical components are modular and allow for quick and efficient switching between various electrical connector configurations. As shown in Figure 5 and Figure 6 , an embodiment of the noise-reducing fluid control valve 100 includes a coil assembly 102 around the valve body 104. The electrical connector 106 connects the valve 100 to a control unit (e.g. Figure 1The control unit 12) shown such that the electric power applied to the coil assembly 102 generates a magnetic field acting on the armature 124 of the valve to open the valve and to allow fluid to flow towards the outlet 128. The inlet end of the valve 100 may include a particle barrier or filter 110 to prevent the circulation of particles that may be present in the fluid. The inlet end and the outlet end of the valve 100 may include seals 112 in the gland to seal the valve 100 to the complementary structure of the manifold 14 or other dispensing device.

[0033] The coil assembly 102 includes a coil 114 wound around a bobbin and connected to an electrical connector 106 to receive electric power to open the valve. The flux washer 116 and the housing 118 form part of the magnetic flux path generated by the coil 114. The valve 100 includes an inlet 120 that also serves as a magnetic pole of the electromagnetic coil. The inlet 120 houses the filter 110, defines the gland for the seal 112, and serves as a main component of the body 104 of the valve 100. The inlet 120 is made of magnetic steel and serves as a magnetic pole of the electromagnetic coil. A non-magnetic metal tube 122 is welded to the lower end of the inlet 120 and surrounds the armature 124. The metal tube 122 can be, for example, non-magnetic stainless steel. The valve member 126 is welded to one end of the armature 124. The armature 124 defines a fluid flow passage 125 that communicates with the central passage 127 of the inlet 120. The valve body 104 includes an outlet 128 welded to the non-magnetic metal tube 122. The outlet 128 defines a valve seat 130 and supports the outlet seal 112. The valve return spring 132 biases the armature 124 away from the inlet 120 (magnetic pole) into the closed position, while the valve member 126 abuts against the valve seat 130. The flux washer 116 can be welded to the inlet 120 and the electromagnetic coil housing 118 to secure the electromagnetic coil assembly 102 to the valve body 104. The electric power applied to the coil 114 generates a magnetic flux that attracts the armature 124 towards the magnetic pole / inlet 120, compresses the return spring 132, and moves the valve member 126 away from the valve seat 130 to allow fluid to flow from the inlet central passage 127 through the armature fluid flow passage 125 and out of the outlet 128 of the valve 100. Using the non-magnetic metal tube 122 forces the magnetic flux through the armature 124 and increases the response time of the valve 100 while potentially reducing power consumption. The non-magnetic tube 122 also forms a structural member of the valve body 104, connecting the inlet 120 to the outlet 128. The disclosed valve construction reduces the parts count and provides a reliable, low-cost electromagnetic actuated valve 100.

[0034] According to an aspect of the present disclosure, the inlet 120 includes a stepped axial hole 123 that defines a shoulder against which the return spring 132 biases. The stepped axial hole 123 includes a second shoulder that supports a shock absorbing element 121 that projects beyond the end face of the magnetic pole / inlet 120. The armature 124 is at Figure 6reciprocates between the closed and open positions shown, where at the open position, when power is applied to coil 114, armature 124 is attracted to pole / port 120. The disclosed damping element 121 is a cylinder whose ends protrude beyond the end face of the pole / port by a distance of at least 0.5 millimeters. The ends of the damping element can be a continuous, flat annular surface, or can be shaped or interrupted to further reduce the surface contact area between the armature and the damping element 121. When armature 124 is attracted towards pole / port 120, armature 124 contacts the damping element 121 and prevents it from directly contacting the pole / port 120. This significantly reduces the noise generated by the actuation of valve 100. Tests show that without the damping element 121, the valve in the manifold produced a peak sound level of 63 dB. An embodiment of the fluid control valve 100 with the damping element 121 mounted in the manifold produced a peak sound level of 53 dB. Since the decibel scale is logarithmic, this 10 dB reduction means that the sound energy emitted from valve 100 including the damping element 121 is reduced by about 10 times relative to Figure 7 the valve shown without the damping element.

[0035] Figure 6 The damping element 121 shown in is an exemplary embodiment of the damping element, and the present disclosure is not limited to this configuration or position of the damping element 121. Optionally, the damping element can be made as part of the armature 124 and can take the form of a cylindrical body of damping material (such as Polyether Ether Ketone (PEEK) plastic) around the return spring 132. Other durable damping materials can be used. In this arrangement, when valve 100 moves to the open position, the damping element will axially protrude beyond the top face of the armature 124 to contact the end face of the pole 120. Whether the damping element 121 is supported by the pole 120 or the armature 124, the configuration of the damping element is not limited to cylindrical, and the position of the damping element is not limited to the central position around the return spring 132. The damping element 121 can be located at any position on the pole 120 or the armature 124 that can absorb the impact between the armature 124 and the pole 120 when the valve 100 opens. This function of the damping element 121 requires that certain parts of the damping element 121 be positioned between the pole 121 and the armature 124 and prevent direct contact between the pole 120 and the armature 124 when the valve 100 opens.

[0036] Figure 7 A second embodiment of a fluid control valve 100 according to aspects of the present disclosure is shown. Figure 7 The control valve 100 of is different from the control valves of Figure 5 and Figure 6 in that the damping element 121 is omitted and a barb outlet connector 128 is incorporated. In all other aspects,Figure 7 The control valve is identical in structure and function to the Figure 5 and Figure 6 control valves.

[0037] The disclosed valve 100 integrates the structure of the inlet and seal 112 with the magnetic poles of the electromagnetic coil to reduce the part count. The configurations of the inlet 120 and seal 112 can be selected to be compatible with the structure of the distribution manifold 114 or other fluid connectors. As Figure 5 and Figure 6 shown, the outlet 128 can be configured to define a seal gland and seal 112, which is similar to the seal gland and seal 112 defined by the inlet 120. Optionally, the outlet 128 can be configured with a barb connector or any other selected outlet connector as Figure 7 shown. The modular valve configuration allows for switching of the outlet connector by selecting different outlet components 128. The coil assembly 102 includes an electrical connector 106 that can be selected to be compatible with alternative connection systems. Different coil assemblies 102 can be replaced to provide the desired configuration of the electrical connector 106.

[0038] Figure 8 and 9 show an embodiment of a distribution manifold 14 in accordance with aspects of the present disclosure. The manifold 14 has a body 140 that supports an inlet 142 and defines fluid distribution channels 144 that connect the inlet 142 to a plurality of outlets 146. The disclosed manifold body 140 defines recesses 148 to support a plurality of valves 100. Each recess 148 includes a hole configured to sealingly engage the inlet 120 of the electromagnetic brake valve 100, and an enlarged area that surrounds and supports the coil assembly 102 of the electromagnetic brake valve 100. The connector 106 of each valve 100 extends from the manifold 14 for connection to a conductor from the control unit 12. In Figure 8 and Figure 9 embodiments, a manifold cap 150 holds the valve 100 in place and defines an outlet hole to sealingly engage the outlet 128 of each valve 100. The manifold cap 150 includes an outlet fitting 152 that, in the Figure 8 and Figure 9 embodiments, is an industry standard quick connect fitting, but any desired outlet fitting can be used. In the Figure 8 and Figure 9 manifolds, the outlet fitting 152 is molded as part of the manifold cap 150 and can be changed as needed by employing a different molded manifold cap 150 without changing the body 140 of the manifold 14.

[0039] Figure 10 shows an alternative distribution manifold 14 configured to receive the Figure 7 valve 100 shown inFigure 10 The distribution manifold differs only in the configuration of the manifold cap 150 from Figure 8 and Figure 9 the distribution manifold shown. In Figure 10 , the manifold cap 150 is configured to allow the integral quick-connect fitting on the outlet 128 of the electromagnetic brake valve 100 to extend out of the manifold 14 for connection to the cleaning fluid conduit 24 (as Figure 1 shown).

[0040] In operation, the functions of the disclosed harsh environment sensor housing and cleaning system 10 are as follows. The vehicle automation and guidance system 34 in communication with the sensor 48 in the housing 16 will determine when the sensor needs to be cleaned. A signal from the vehicle automation and guidance system 34 will be sent to the control unit 12 to initiate a cleaning cycle in one or more of the sensor housings 16. The control unit will activate the pump in the cleaning fluid reservoir 20 to generate fluid pressure in the distribution manifold 14. Then, the control unit 12 will power one or more valves 100 to open the valves 100 and deliver the cleaning fluid to the corresponding sensor housing 16. While the valves 100 are open, the cleaning fluid will be sprayed from the nozzle 92 into the lens cleaning space 90. The control unit 12 will also power the motor 50 in the corresponding sensor housing 16 to rotate the cylindrical lens 80, moving the dirty portion of the lens 80 into the lens cleaning space 90, where the cleaning fluid helps remove contaminants from the surface of the lens 80. The vertical edge 89 of the sensor opening 58 scrapes large debris from the surface of the lens 80, and as the lens 80 rotates, the wiper 88 continues to remove material from the surface of the lens 80. Then, the wet and clean surface portion of the lens 80 is rotated out of the lens cleaning space 90 and past a second set of wipers 88, which remove any remaining cleaning fluid and any remaining debris from the surface of the lens 80. Then, the vehicle automation and guidance system 34 determines whether the lens 80 has been cleaned, and if not, repeats the cleaning cycle until the lens 80 is clean enough for the camera or sensor 48 to be operational. Then, the control unit 12 shuts off the pump in the cleaning fluid reservoir 20, closes the corresponding valves 100 and shuts off the motor 50 in the corresponding sensor housing 16. The cleaning cycle may also include operation of the pump to draw back the used cleaning fluid from the return conduit 30 and drain the cleaning fluid in the lens cleaning space 90 out of the housing outlet 94.

[0041] Facilitated by a pump associated with the recycle filter 18, the used cleaning fluid flows out of the lens cleaning space 90 through the outlet 94. The used cleaning fluid can be filtered and returned to the cleaning fluid reservoir 20, or accumulated in a tank (not shown) for later filtering and reuse or proper disposal. The disclosed sensor housing 16 protects the sensor 48 and provides an effective means of cleaning the surface of the lens 80, through which the sensor 48 actively or passively queries the surrounding environment. The disclosed system 10 captures the used cleaning fluid to reduce environmental pollution and can reduce vehicle downtime by automating the cleaning process of the sensors required for vehicle operation.

[0042] Figure 11 and Figure 12 An alternative sensor housing 16a incorporating a flat, disc-shaped lens 80a is schematically shown. In this configuration of the sensor housing 16a, the sensor opening 58 is semi-circular and has an edge in a plane, such that the opening 58 is compatible with the flat lens 80a. The disc-shaped (flat, circular) lens 80a is arranged to enclose the sensor opening 58 and protect the sensor 48 within the sensor chamber 56. The motor 50 is connected to the lens 80a by a shaft 54 so as to rotate the lens 80a when controlled by a control unit (such as Figure 1 the control unit 12 shown in). The connection between the lens 80a and the shaft 54 can be a fastener extending through a hole in the lens 80a, or other connection that will ensure the lens 80a rotates with the shaft 54. In the housing 16a, the cleaning space 90 is defined on one side of the housing 16a, and the sensor 48 is arranged on the opposite side of the housing 16a. The fluid conduit 24 delivers the cleaning fluid to a cleaning fluid nozzle located within the cleaning space 90, and the cleaning fluid outlet 94 is arranged to remove the used cleaning fluid from the cleaning space 90. Except for the difference in the structure of the sensor housing 16a, the embodiment of the sensor housing 16a and its functions are the same as Figures 2 to 4 the embodiment of the sensor housing 16. As needed or according to a predetermined schedule, the lens 80a is rotated 180° so that the half of the lens 80a exposed to environmental elements is located within the cleaning space. The cleaning fluid is delivered to the cleaning space 90 to remove substances from the exterior of the lens 80a, and the cleaning fluid is removed from the cleaning space 90 through the cleaning fluid outlet 94. Next time, the lens 80a is rotated 180°, and the clean portion of the lens 80a is in front of the camera or sensor 48.

[0043] It can be seen that the sensor opening in this embodiment is elongated in the vertical direction and narrow in the horizontal direction. The sensor housing can be oriented perpendicular to the shown position, at which the sensor opening 58 will be elongated in the horizontal direction and narrowed in the vertical direction. The orientation of the sensor housing 16a can be selected to match the visual range required by the camera or sensor 48 within the housing 16a. For example, a counterclockwise rotationFigure 12 The sensor housing 16a is oriented 90°, with the sensor opening 58 at the top of the housing 16a and the cleaning space 90 at the bottom of the housing 16a. This orientation will provide a horizontally elongated sensor opening 58 and allow gravity to help contain the cleaning flow in the cleaning space 90. The sensor housing 16a can also be oriented vertically or horizontally to maximize the effectiveness of the camera or sensor within the housing. By selecting the sensor and motor components, the sensor housing 16a can be made to have a very small depth to reduce the visibility of the sensor housing.

[0044] Figure 14 and Figure 15 FIG. shows a third embodiment of a sensor housing 16b according to aspects of the present disclosure. The sensor housing 16b includes a hemispherical lens 80b, the lower edge of which is received in a lens mounting plate 78 and is connected to a motor 50 by a motor shaft 54. The hemispherical lens defines a sensor housing for a camera or sensor 48. A cleaning space 90 is defined on the opposite side of the sensor housing. A cleaning flow is provided to the cleaning space 90 via a conduit 24 and a nozzle 92, and the used cleaning flow is removed via a cleaning flow outlet 94. When the lens 80b is rotated by the motor 50, a semi-circular wiper removes the cleaning flow and debris from the outer surface of the lens 80b. The orientation of the camera or sensor 48 within the sensor housing 16b can be selected to most effectively utilize the hemispherical window provided by the hemispherical lens 80b. Figure 14 FIG. shows a camera or sensor 48 oriented at an acute angle with respect to the side of the sensor housing 16b, while Figure 15 FIG. shows a camera or sensor oriented parallel to the side of the sensor housing 16b. Although Figures 11 to 12 the sensor housing 16a and the sensor housing 16b in FIG. are shown as square or rectangular, the shape of the sensor housing is not limited to these shapes, which are used for convenience. The shape of the sensor housing can be circular and have the minimum size required to meet its function. Similarly, the shape of the lenses 80, 80a, 80b can be selected to minimize the size and volume of the sensor housing.

[0045] Figure 13 FIG. shows an alternative use of the disclosed fluid control valve 100 in a system using compressed air. In Figure 13In the system, a compressed air source (such as compressor 31) is connected to a manifold 14 which has five fluid control valves 100 arranged to control the flow of compressed air to each of five sensors disposed on the vehicle. The controller 12 is connected to selectively open the fluid control valves 100 under the direction of the vehicle control and communication system 34. When the fluid control valves 100 are open, compressed air is delivered through a nozzle 41 which is positioned to sweep water or debris from the sensor 48. In this example, the sensor will have its own housing on which water or other substances can accumulate and impair the function of the sensor. A short burst of pressurized air can be used to remove the water or debris and restore sensor function.

Claims

1. A sensor housing and cleaning system, comprising: A plurality of sensor housings, each sensor housing comprising: A sensor chamber in which a sensor or a camera is supported, the sensor or the camera receiving information from the environment; A sensor opening through the sensor housing for enabling the sensor or the camera to receive information from the environment; A transparent lens spanning the sensor opening, the lens having an outer surface exposed to the environment surrounding the sensor housing; A lens cleaning space located within the sensor housing adjacent to a portion of the outer surface of the lens that is not within the sensor opening, the lens cleaning space being arranged to clean the portion of the outer surface of the lens, the lens cleaning space being substantially sealed off from the environment surrounding the sensor housing; A cleaning flow nozzle arranged to direct a cleaning flow at the outer surface of the lens within the lens cleaning space; and A cleaning flow outlet for discharging the cleaning flow from the lens cleaning space; and A motor having a shaft coupled to the lens for rotating the lens to move a portion of the lens from the sensor window to the lens cleaning space; A cleaning flow source connected to the cleaning flow nozzle of each of the sensor housings; A cleaning flow collection system for collecting the cleaning flow discharged from the cleaning flow outlet of the sensor housing; A control unit connected to each of the sensor housings, the cleaning flow source, and a vehicle system, the vehicle system receiving data from the sensor or the camera within each sensor housing, the control unit being connected to supply power to the motor and to control the delivery of the cleaning flow to the lens cleaning space of each sensor housing; Wherein the control unit responds to a signal from the vehicle system to clean the cylindrical lens of one or more sensor housings, the control unit in response to the signal starts to deliver the cleaning flow to the lens cleaning space of the one or more sensor housings and causes the motor to rotate the lens such that a portion of the lens spanning the sensor opening moves through the lens cleaning space and the clean portion of the lens moves to span the sensor opening, and the used cleaning flow is discharged from the lens cleaning space for collection.

2. The sensor housing and the cleaning system according to claim 1, wherein, The lens is rotationally symmetric.

3. The sensor housing and cleaning system according to claim 1 or 2, wherein, The lens has a shape selected from the group consisting of cylindrical, flat circular, hemispherical, and convex dome shapes.

4. The sensor housing and cleaning system according to any one of the preceding claims, comprising: A cleaning flow supply conduit connected to deliver the cleaning flow to the cleaning flow nozzle of each sensor housing; A distribution manifold connected to the cleaning flow source to receive the cleaning flow and connected to the cleaning flow conduits of a plurality of the sensor housings, the distribution manifold including a valve arranged to fluidly connect or interrupt the cleaning flow source and the cleaning flow conduit connected to one of the sensor housings in response to a signal from the control unit.

5. The sensor housing and cleaning system according to any one of the preceding claims, wherein the cleaning flow collection system comprises: A reservoir for the used cleaning fluid stream, for collecting the cleaning fluid stream discharged from the cleaning fluid outlet of the sensor housing.

6. The sensor housing and cleaning system according to any one of the preceding claims, wherein, The cleaning fluid collection system includes: A pump, arranged to push the used cleaning fluid through a filter; and A fluid conduit, connecting the filter to the cleaning fluid source; Wherein, the used cleaning fluid is cleaned and returned to the reservoir of the cleaning fluid for reuse in the sensor housing.

7. The sensor housing and cleaning system according to claim 4, wherein, The fluid distribution manifold includes: A body, supporting an inlet and defining fluid distribution channels connecting the inlet to a plurality of outlets, the body defining a plurality of recesses, each recess having a hole in fluid communication with one of the plurality of outlets; A plurality of solenoid-operated valves, one solenoid-operated valve arranged in each recess, the inlet of the solenoid-operated valve sealingly engaging with the hole, each solenoid-operated valve including an outlet axially opposite to the inlet; and A manifold cap, arranged to hold the solenoid-operated valve in the recess, the manifold cap defining an outlet opening through which fluid exits the manifold; Wherein, the solenoid-operated valve is opened to fluidly connect the fluid distribution channel to one of the outlet openings in the manifold cap.

8. The sensor housing and cleaning system according to claim 7, wherein, The manifold cap includes an outlet fitting in fluid communication with each outlet opening in the manifold cap, and the manifold cap defines an outlet hole facing the solenoid-actuated valve, the outlet of each solenoid-operated valve being received in each outlet hole in a sealed relationship.

9. The sensor housing and cleaning system according to claim 7 or 8, wherein, Each solenoid-actuated valve includes an integral outlet fitting extending through the outlet opening in the manifold cap.

10. A fluid control valve, comprising: A valve body, including an inlet, an outlet, and a tubular body extending between the inlet and the outlet; The inlet is constructed of magnetic metal and defines an axial fluid flow channel, the inlet including an integral inlet coupler located at the first end of the inlet for connecting the valve to a fluid conduit, the second end of the inlet being connected to the tubular body and facing the armature; The outlet defines an axial flow channel and includes an integral outlet coupler located at the second end of the outlet for connecting to a fluid conduit, the first end of the outlet facing the second end of the inlet, the outlet including a valve seat surrounding the axial flow channel; The tubular body is constructed of non-magnetic metal, the tubular body extending from a first end welded to the second end of the inlet to a second end welded to the first end of the outlet; An armature, arranged in the space surrounded by the tubular body and axially arranged between the second end of the inlet and the first end of the outlet, the armature having a stop surface adjacent to the second end of the inlet and supporting a valve member facing the valve seat, the armature being biased away from the second end of the inlet and entering a closed position when the valve member engages the valve seat through an armature return spring, the armature defining a fluid flow path from the stop surface to the region surrounding the valve member and adjacent to the valve seat; And The electromagnetic coil assembly includes a coil surrounding the tubular body and an axial gap between the second end of the inlet and the stop surface of the armature. The electromagnetic coil assembly includes a magnetic member that, when power is applied to the coil, completes the magnetic flux path of the magnetic flux generated by the coil. The magnetic flux path extends through the second end of the inlet and the armature; Wherein, the inlet forms the magnetic pole of the electromagnetic coil and includes the inlet connector, and the outlet defines the valve seat and includes the outlet connector.

11. The fluid control valve according to claim 10, comprising a non-metallic shock-absorbing element located between the second end of the inlet and the stop surface of the armature, the shock-absorbing element preventing direct contact between the stop surface of the armature and the second end of the inlet.

12. The fluid control valve according to claim 11, wherein, The shock-absorbing element is a plastic cylinder surrounding the axial fluid flow channel of the inlet, and the ends of the cylinder protrude beyond the second end of the inlet.

13. The fluid control valve according to claim 11 or 12, wherein, The shock-absorbing element is constructed of PEEK.

14. The fluid control valve according to claims 11 to 13, wherein, The ends of the cylinder protrude beyond the second end of the inlet by at least 0.5 mm.

15. A method of assembling the fluid control valve according to claim 10, comprising: Welding the tubular body to the first end of the outlet; Placing the armature and the connected valve member in the space surrounded by the tubular body, the valve member abutting against the valve seat; Arranging the armature return spring in the groove defined in the stop surface of the armature; Inserting the second end of the inlet into the tubular body such that the armature return spring is received in the groove defined by the second end of the inlet; Advancing the second end of the inlet into the tubular body until the axial gap between the stop surface of the armature and the second end of the inlet reaches a predetermined axial distance; And Welding the second end of the inlet to the tubular body.

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