Vehicle vision system

Abstract

The present disclosure provides a "vehicle vision system". A vision sensor includes a housing, a lens, a circuit board, an image sensor, and an actuator. The housing defines an interior cavity and an aperture providing access to the interior cavity. The lens is disposed within the aperture, fixed to the housing such that a position of the lens is fixed relative to the housing, and defines a focal plane within the interior cavity. The circuit board is disposed within the internal cavity and fixed to the housing such that a position of the circuit board is fixed relative to the housing and relative to the lens. The image sensor is disposed within the internal cavity and is connected to the circuit board. The actuator is configured to adjust a position of the image sensor relative to the circuit board to align the image sensor with the focal plane.

Description

Technical Field

[0001] This disclosure relates to vehicles and visual sensors configured to observe the immediate surrounding environment of the vehicle. Background Technology

[0002] Vehicles and automobiles may include sensing systems configured to provide notifications about the vehicle’s surroundings and to provide inputs to various vehicle subsystems. Summary of the Invention

[0003] A vision system for a vehicle includes a housing, a lens, a printed circuit board, an electrical connector, an electrical interface, an image sensor, and an actuator. The housing defines an internal cavity, a first orifice providing passage to the internal cavity, and a second orifice providing passage to the internal cavity. The lens is fixed to the housing, disposed within the first orifice, and defines a focal plane within the internal cavity. The printed circuit board is disposed within the internal cavity. The electrical connector is fixed to the housing and externally disposed on the opposite side of the second orifice relative to the internal cavity. The electrical interface extends from the printed circuit board through the second orifice and reaches the electrical connector. The electrical interface establishes an electrical connection between the printed circuit board and the electrical connector, is fixed to the housing within the second orifice, and fixes the position of the printed circuit board within the internal cavity. The image sensor is disposed within the internal cavity and electrically connected to the printed circuit board. The actuator is disposed on the printed circuit board and configured to adjust the position of the image sensor relative to the printed circuit board to align the image sensor with the focal plane.

[0004] A vision sensor includes a housing, a lens, a circuit board, an image sensor, and an actuator. The housing defines an internal cavity and an aperture providing passageway to the internal cavity. The lens is disposed within the aperture, fixed to the housing such that its position is fixed relative to the housing, and defines a focal plane within the internal cavity. The circuit board is disposed within the internal cavity and fixed to the housing such that its position is fixed relative to the housing and relative to the lens. The image sensor is disposed within the internal cavity and connected to the circuit board. The actuator is configured to adjust the position of the image sensor relative to the circuit board to align the image sensor with the focal plane.

[0005] A method for manufacturing a vision sensor having a lens, a circuit board, and an image sensor, the method comprising: positioning the lens on a base structure of the vision sensor; positioning the circuit board on the base structure and relative to the lens; attaching the image sensor to the circuit board via at least one actuator; and adjusting the position of the image sensor relative to the circuit board via the at least one actuator to align the image sensor with a focal plane defined by the lens. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of a vehicle equipped with a vision system and one or more corresponding vision sensors;

[0007] Figure 2 This is a schematic diagram of a vision sensor;

[0008] Figure 3 This is a schematic diagram of a first type of actuator configured to adjust the position of an image sensor that forms part of a vision sensor;

[0009] Figure 4 This is a schematic diagram of a second type of actuator configured to adjust the position of an image sensor; and

[0010] Figure 5 This is a flowchart of a method for manufacturing vision sensors. Detailed Implementation

[0011] This document describes embodiments of the present disclosure. However, it should be understood that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as a representative basis for teaching those skilled in the art to employ the embodiments in different ways. As will be understood by those skilled in the art, various features shown and described with reference to any of the drawings may be combined with features shown in one or more other drawings to produce embodiments not explicitly shown or described. The combinations of features shown provide representative embodiments for typical applications. However, for a particular application or implementation, various combinations and modifications of features consistent with the teachings of this disclosure may be desired.

[0012] One of the key steps in automotive camera manufacturing is focus alignment. The lens needs to be precisely aligned with the image sensor to achieve the desired level of image quality. In today's camera manufacturing processes, the image sensor is rigidly mounted to a circuit board before focus alignment. During focus alignment, according to current processes, the circuit board is manipulated along its X, Y, and Z positions and along its tilt angle relative to the lens, so that the image sensor is precisely aligned with the focal plane defined by the lens. The circuit board is then permanently secured in its precise position relative to the lens using an adhesive. The adhesive is then cured in an oven.

[0013] This lens alignment process is complex and requires expensive equipment, resulting in high manufacturing costs. First, the process requires an active alignment machine to identify the optimal six-DOF focal position and tilt angle. Then, the circuit board must be precisely manipulated to that position and tilt angle, and adhesive is applied to hold the board in place. The assembly is then moved to a curing oven to allow the adhesive to cure. The final position of the circuit board is at an angle relative to the camera connector, and this angle varies for each manufactured automotive camera. The angle between the tilted circuit board and the camera connector requires complex interface components to ensure a reliable electrical connection, leading to increased costs and a larger camera size. In some applications, such as advanced driver assistance systems and 360° cameras, there is a subsequent calibration process after the camera has been installed in the vehicle.

[0014] The idea disclosed in this paper is a modification to the lens alignment process in camera manufacturing, which reduces manufacturing costs and improves camera reliability. Manufacturing costs are reduced by eliminating the need for an active alignment machine and curing oven through the use of an image sensor actuator capable of translating and tilting the image sensor. It also improves reliability by reducing the tilt angle of the circuit board relative to the camera housing and interconnect components.

[0015] As with current processes, the image sensor chip is attached to the circuit board before lens alignment begins. The circuit board is then secured to the camera housing. This can be accomplished with standard manufacturing tolerances, eliminating the need for production equipment to determine the deviation between the lens and the circuit board, or equipment to manipulate the circuit board to align the image sensor with the lens's focal plane. The image sensor is then manipulated using an image sensor actuator at X, Y, and Z positions along the circuit board and at an angle of tilt relative to the lens. This requires no manufacturing equipment and can optionally occur at the camera manufacturing facility in subsequent steps, during alignment / calibration steps in vehicle assembly, or during in-line calibration processes while the vehicle is in motion after production. During this process, the image sensor actuator moves the image sensor relative to the circuit board, ensuring precise alignment of the image sensor with the lens's focal plane. Simpler camera mounting devices and targets can be used instead of the complex mounting devices and equipment used in current processes.

[0016] The image sensor's position is stored in memory, so at each subsequent power cycle, the camera can read the stored position from memory and move the sensor to its alignment position. As the camera ages, the image sensor's position along the z-axis of the circuit board and the tilt angle between the lens and the image sensor will undergo slight changes. Currently, there is no mechanism to compensate for these aging-induced changes, but the addition of the proposed image sensor actuator may enable compensation for these aging-induced changes and reduce the impact of aging-related image quality degradation.

[0017] refer to Figure 1 A schematic diagram of vehicle 10 is shown. The vehicle may include a sensing system or vision system, which includes one or more cameras or vision sensors 12. The vision sensors 12 may communicate with a controller 14. The controller 14 may be programmed to control various vehicle subsystems based on selected modes and / or various conditions input into the controller 14. For example, the controller 14 may be configured to control vehicle maneuvers based on inputs received from the vision sensors 12 (e.g., once an adaptive cruise control system is activated to maintain a desired distance between the front of vehicle 10 and another vehicle detected by one or more of the vision sensors 12; and / or the controller 14 may be configured to control the speed of vehicle 10, the deceleration of vehicle 10, and the steering of vehicle 10 to maneuver away from objects detected by one or more of the vision sensors 12). The controller 14 may also be configured to output views from one or more of the vision sensors 12 to a display screen that can be viewed by the vehicle operator (e.g., the controller 14 may perform a reversing assist operation, wherein a rear view of vehicle 10 is output to a display screen that can be viewed by the driver of vehicle 10). Such vision sensors 12 can also be used inside the passenger compartment of vehicle 10 (for example, some vision sensors 12 can be mounted on the dashboard or ceiling to view the driver and other occupants).

[0018] Although shown as a single controller, controller 14 may be part of a larger control system and may be controlled by various other controllers throughout vehicle 10, such as the vehicle system controller (VSC). Therefore, it should be understood that controller 14 and one or more other controllers may be collectively referred to as “controllers”, which control various actuators in response to signals from various sensors to control the functions of vehicle 10 or vehicle subsystems. Controller 14 may include a microprocessor or central processing unit (CPU) that communicates with various types of computer-readable storage devices or media (e.g., non-transitory computer-readable media on which instructions are stored). Computer-readable storage devices or media may include volatile and non-volatile storage devices such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operational variables when the CPU is powered off. The computer-readable storage device or medium may be implemented using any of a number of known memory devices, such as PROM (programmable read-only memory), EPROM (electric PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combined memory device capable of storing data, some of which represent executable instructions for the controller 14 to control the vehicle 10 or vehicle subsystems.

[0019] The control logic or functions executed by controller 14 can be represented by flowcharts or similar diagrams in one or more accompanying figures. These figures provide representative control strategies and / or logic that can be implemented using one or more processing strategies, such as event-driven, interrupt-driven, multitasking, multithreading, etc. For this purpose, the various steps or functions shown may be executed in the order shown, in parallel, or omitted in some cases. Although not always explicitly shown, those skilled in the art will recognize that one or more of the shown steps or functions may be repeatedly executed depending on the specific processing strategy used. Similarly, the processing order is not necessarily necessary to achieve the features and advantages described herein, but is provided for ease of illustration and description. The control logic may be implemented primarily in software, executed by a microprocessor-based vehicle, engine, and / or powertrain controller (such as controller 14). Of course, depending on the specific application, the control logic may be implemented in one or more controllers in software, hardware, or a combination of software and hardware. When implemented in software, the control logic may be provided in one or more computer-readable storage devices or media storing data representing code or instructions executed by a computer to control a vehicle or vehicle subsystem. Computer-readable storage devices or media may include one or more of a number of known physical devices that utilize electrical storage, magnetic storage and / or optical storage to store executable instructions and associated calibration information, operating variables, etc.

[0020] Controller 14 can be configured to receive via electrical signals Figure 1 The various states or conditions of the various vehicle components are shown. The electrical signals can be delivered from the various components to the controller 14 via input channels. Additionally, the electrical signals received from the various components can indicate requests or commands for changing or altering the state of one or more of the corresponding components of the vehicle 10. The controller 14 includes output channels configured to deliver requests or commands (via electrical signals) to the various vehicle components. The controller 14 includes control logic and / or algorithms configured to generate requests or commands delivered via the output channels based on the requests, commands, states, or conditions received from the various vehicle components via the input channels.

[0021] Input and output channels in Figure 1 The lines are shown as dashed lines. It should be understood that a single dashed line can represent both an input channel and an output channel entering or leaving a single element. Furthermore, an output channel exiting from one element can operate as an input channel to another element, and vice versa.

[0022] refer to Figures 2 to 4 The vision system is shown in further detail. More specifically, one of the vision sensor 12 and the controller 14 is... Figure 2 As shown in the diagram, part of the vision sensor 12 is in Figure 3 and Figure 4 As shown in the diagram. The vision sensor 12 may include a basic structure, such as a housing 16. The housing 16 may define an internal cavity 18. The housing 16 may also define a first aperture 20 providing passage to the internal cavity 18. The housing 16 may also define a second aperture 22 providing passage to the internal cavity 18. A lens 24 is fixed to the housing 16. The lens 24 is disposed within the first aperture 20. The lens 24 defines a focal plane 26 within the internal cavity 18. The lens 24 may be fixed to the housing such that the position of the lens 24 is fixed relative to the housing 16. More specifically, the first aperture 20 may include a second cavity having an inlet aperture 28 and an outlet aperture 30.

[0023] The vision sensor 12 may also include a printed circuit board 32. The printed circuit board 32 is disposed within the internal cavity 18 and fixed to the housing 16 such that the position of the printed circuit board 32 is fixed relative to the housing 16 and relative to the lens 24. An electrical connector 34 is fixed to the housing 16. The electrical connector 34 is disposed outside the housing 16 and is positioned on the opposite side of the second aperture 22 relative to the internal cavity 18. The electrical connector 34 is also disposed outside the housing 16 and is positioned on the opposite side of the housing 16 relative to the internal cavity 18.

[0024] The electrical interface 36 can extend from the printed circuit board 32. More specifically, the electrical interface 36 can extend from the printed circuit board 32 through the second aperture 22 and reach the electrical connector 34. The electrical interface 36 can establish an electrical connection between the printed circuit board 32 and the electrical connector 34. The electrical interface 36 can be secured to the housing 16 within the second aperture 22. The electrical interface 36 can physically secure the printed circuit board 32 to the housing 16 and fix the position of the printed circuit board 32 relative to the housing 16 within the internal cavity 18. The electrical connector 34 and the electrical interface 36 may include a base structure (such as a housing or enclosure) and electrical components (e.g., wires, contacts, etc.) secured to or housed within such a base structure. The electrical components of the electrical connector 34 and the electrical interface 36 establish an electrical connection between the electrical connector 34, the electrical interface 36 and the printed circuit board 32, while the housing or enclosure of the electrical connector 34 and the electrical interface 36 provides a rigid structure for the electrical connector 34 and the electrical interface 36, which operates to maintain the relative position of the electrical connector 34 and the electrical interface 36.

[0025] The vision sensor 12 may also include an image sensor 38. The image sensor 38 may be an image sensor chip, a rod-shaped image sensor, a complementary metal-oxide-semiconductor (CMOS) sensor, or any other type of sensor known in the art capable of capturing images. The image sensor 38 is disposed within the internal cavity 18. The image sensor 38 is electrically connected to a printed circuit board 32. An actuator 40 is configured to adjust the position of the image sensor 38 relative to the circuit board 32 to align the image sensor 38 with the focal plane 26 defined by the lens 24. The actuator 40 may be disposed within the internal cavity 18. The actuator 40 may also be disposed on and / or physically connected to the printed circuit board 32. The actuator 40 may also be electrically connected to the printed circuit board 32. The actuator 40 may be an electric solenoid, an electric motor (e.g., a servo motor), an electric cylinder, or any other actuator known in the art.

[0026] Controller 14 can be electrically connected to printed circuit board 32, image sensor 38, and actuator 40 via electrical connector 34 and electrical interface 36. Controller 14 can be programmed to operate actuator 40 to adjust the position of image sensor 38 relative to printed circuit board 32 to align image sensor 38 with focal plane 26. Controller 14 can also be programmed to store the desired position of image sensor 38 (e.g., the position of image sensor 38 relative to printed circuit board 32 corresponding to alignment of image sensor 38 with focal plane 26 defined by lens 24) in electronic memory (e.g., computer-readable storage device or medium). Image sensor 38 in Figure 3 It is shown in the middle as aligned with the focal plane 26, and in Figure 4The center is not aligned with the focal plane 26.

[0027] The controller 14 can also be programmed to operate the actuator 40 to reposition the image sensor 38 to the desired position in response to the initiation of a power cycle (e.g., turning the ignition of the vehicle 10 to the "on" position) and the image sensor 38 not being in the desired position. The controller 14 can also be programmed to update the desired position of the image sensor 38 and operate the actuator 40 to reposition the image sensor 38 to the updated desired position in response to a change in the desired position of the image sensor 38. The desired position can change due to wear or displacement of components of the vision sensor 12, resulting in a deviation between the image sensor 38 and the focal plane 26. This deviation may occur over an extended period of time or in response to the end of a power cycle (e.g., turning the ignition of the vehicle 10 to the "off" position).

[0028] Actuator 40 may include one or more actuators and may be configured to linearly translate image sensor 38 relative to printed circuit board 32, or to rotate or pivot image sensor 38 relative to printed circuit board 32. One or more actuators may linearly translate image sensor 38 in multiple directions relative to printed circuit board 32 (e.g., according to a Cartesian coordinate system having X-axis, Y-axis, and Z-axis, wherein the X-axis and Y-axis define the outer surface of printed circuit board 32, the image sensor 38 may be linearly translated in directions along the X-axis and Y-axis and along the outer surface of printed circuit board 32 and / or in directions along the Z-axis toward or away from the outer surface of printed circuit board 32).

[0029] Figure 3 An example of an actuator 40 configured to linearly translate an image sensor 38 along the outer surface of a printed circuit board 32 is shown. In this example, the image sensor 38 is slidably fixed to the printed circuit board 32 via a linear guide 42 (such as a linear guide rail). The actuator 40, in the form of an electric solenoid or electric cylinder, is fixed to the printed circuit board 32, attached to the image sensor 38, and configured to linearly slide the image sensor 38 forward and backward in directions 44 and 45. The actuator 40 may include a push rod 46 attached to the image sensor 38. The push rod 46 is configured to extend to push the image sensor 38 in the forward direction 44 and retract to pull the image sensor 38 in the backward direction 45. It should be understood that... Figure 3 The configuration described herein is for illustrative purposes, and any linear translation system known in the art can be used to linearly adjust the position of the image sensor 38 relative to the printed circuit board.

[0030] One or more actuators may rotate or pivot the image sensor 38 in multiple directions relative to the printed circuit board 32 (e.g., the image sensor 38 may rotate about the X, Y, and Z axes relative to the printed circuit board 32 according to a Cartesian coordinate system having an X-axis, a Y-axis, and a Z-axis, wherein the X-axis and the Y-axis define the outer surface of the printed circuit board 32). Figure 4 An example of an actuator 40 configured to rotate or pivot an image sensor 38 relative to a printed circuit board 32 is shown. In this example, the image sensor 38 is rotatably fixed to the printed circuit board 32 via a hinge or pivot 48. The actuator 40, in the form of an electric solenoid or electric cylinder, is fixed to the printed circuit board 32, attached to the image sensor 38, and configured to rotate or pivot the image sensor 38 in relative rotational directions 50, 52. The actuator 40 may include a push rod 54 attached to the image sensor 38 via a pin connection 56. The push rod 54 is configured to rotate or pivot about the pin connection 56. The push rod 46 is configured to unfold to push the pin connection 56 away from the printed circuit board 32, thereby causing the image sensor to rotate or pivot relative to the printed circuit board 32 in direction 50. The push rod 46 is configured to retract to pull the pin connection 56 toward the printed circuit board 32, thereby causing the image sensor 38 to rotate or pivot relative to the printed circuit board 32 in direction 52. It should be understood that... Figure 4 The configuration described herein is for illustrative purposes, and any rotation or pivoting system known in the art can be used to rotate or pivot the image sensor 38 relative to the printed circuit board 32.

[0031] refer to Figure 5 The diagram illustrates a method 100 for manufacturing a vision sensor 12 and adjusting the position of an image sensor 38. Method 100, or at least a portion thereof, may be stored as control logic, algorithms, and / or instructions on a non-transitory computer-readable medium executable by a processor or controller (e.g., controller 14).

[0032] Method 100 begins at block 102, where the position of lens 24 is secured to the base structure (e.g., housing 16) of vision sensor 12. The method then proceeds to block 104, where the position of printed circuit board 32 is secured to the base structure (e.g., housing 16) of vision sensor 12 and relative to lens 24. Image sensor 38 is then attached to printed circuit board 32 via one or more actuators 40. Image sensor 38 may be attached to printed circuit board 32 prior to securing printed circuit board 32 to base structure (e.g., housing 16). More precisely, the step at block 106 may occur prior to the step at block 104. Then, at block 108, the position of image sensor 38 relative to circuit board 32 is adjusted via one or more actuators 40 to align image sensor 38 with focal plane 26 defined by lens 24. Adjusting the position of image sensor 38 may correspond to linearly translating image sensor 38 relative to circuit board 32, or rotating or pivoting image sensor 38 relative to circuit board 32.

[0033] Next, at block 110, the desired position of the image sensor 38 (e.g., the position of the image sensor 38 relative to the printed circuit board 32, corresponding to the alignment of the image sensor 38 with the focal plane 26 defined by the lens 24) is stored in electronic memory (e.g., a computer-readable storage device or medium). Then, at block 112, method 100 determines whether the desired position of the image sensor 38 has changed. If the desired position of the image sensor 38 has not changed, method 100 ends at block 114. If the desired position of the image sensor 38 has changed (e.g., due to a change in the position of the lens 24 and / or the focal plane 26 or due to a change in the position of the printed circuit board 32 to which the image sensor 38 is attached), method 100 proceeds to block 116, where the desired position of the image sensor 38 is updated and the updated desired position (e.g., the new position where the image sensor 38 is realigned with the focal plane 26) is stored in electronic memory. Then, method 100 proceeds to box 118, where the position of image sensor 38 is adjusted to reposition image sensor 38 to the updated desired position. The timing order of boxes 116 and 118 can be changed, so the position of image sensor 38 is adjusted first until controller 14 recognizes that image sensor 38 is focused and realigned with focal plane 26, and then the new position of image sensor 38 focused and realigned with focal plane 26 is recorded as the updated desired position. After completing the steps at box 118, the method ends at box 114.

[0034] It should be understood that Figure 5 The flowcharts in this document are for illustrative purposes only, and method 100 should not be construed as limited to... Figure 5The flowchart in Method 100. Some steps of Method 100 can be rearranged, while other steps can be omitted entirely.

[0035] It should be understood that the names of any component, state, or condition described herein, such as first, second, third, fourth, etc., may be rearranged in the claims such that they are chronologically ordered with respect to the claims. Furthermore, it should be understood that any component, state, or condition without a numerical name described herein may be given the names first, second, third, fourth, etc., in the claims if one or more of a particular component, state, or condition is claimed.

[0036] The terms used in this specification are descriptive rather than limiting, and it should be understood that various changes may be made without departing from the spirit and scope of this disclosure. As previously stated, features of the various embodiments may be combined to form other embodiments that may not be explicitly described or shown. While various embodiments may have been described as providing advantages or preferences over other embodiments or prior art implementations in terms of one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be compromised to achieve desired overall system properties, depending on the specific application and implementation. Therefore, embodiments described as less desirable in terms of one or more characteristics than those desired by other embodiments or prior art implementations are within the scope of this disclosure and may be desirable for a particular application.

[0037] According to the present invention, a vision system for a vehicle is provided, the vision system comprising: a housing defining an internal cavity, a first aperture providing a passage to the internal cavity, and a second aperture providing a passage to the internal cavity; a lens fixed to the housing, disposed within the first aperture, and defining a focal plane within the internal cavity; a printed circuit board disposed within the internal cavity; an electrical connector fixed to the housing and externally disposed on the opposite side of the second aperture relative to the internal cavity; an electrical interface extending from the printed circuit board through the second aperture and reaching the electrical connector, wherein the electrical interface establishes an electrical connection between the printed circuit board and the electrical connector, is fixed to the housing within the second aperture, and fixes the position of the printed circuit board within the internal cavity; an image sensor disposed within the internal cavity and electrically connected to the printed circuit board; and an actuator disposed on the printed circuit board and configured to adjust the position of the image sensor relative to the printed circuit board to align the image sensor with the focal plane.

[0038] According to an embodiment, the invention is further characterized by a controller programmed to operate the actuator to adjust the position of the image sensor relative to the printed circuit board to align the image sensor with the focal plane.

[0039] According to an embodiment, the desired position of the image sensor relative to the printed circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) in response to the initiation of a power cycle and the image sensor not being in the desired position, operate the actuator to reposition the image sensor to the desired position.

[0040] According to an embodiment, the desired position of the image sensor relative to the printed circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) update the desired position of the image sensor and operate the actuator to reposition the image sensor to the updated desired position in response to a change in the desired position.

[0041] According to an embodiment, the actuator is configured to linearly translate the image sensor relative to the printed circuit board.

[0042] According to an embodiment, the actuator is configured to rotate the image sensor relative to the printed circuit board.

[0043] According to the present invention, a vision sensor is provided, the vision sensor comprising: a housing defining an internal cavity and an aperture providing a passage to the internal cavity; a lens disposed within the aperture and fixed to the housing such that the position of the lens is fixed relative to the housing and defines a focal plane within the internal cavity; a circuit board disposed within the internal cavity and fixed to the housing such that the position of the circuit board is fixed relative to the housing and relative to the lens; an image sensor disposed within the internal cavity and connected to the circuit board; and an actuator configured to adjust the position of the image sensor relative to the circuit board to align the image sensor with the focal plane.

[0044] According to an embodiment, the invention is further characterized by an electrical connector fixed to the housing and disposed externally on the opposite side of the housing relative to the internal cavity.

[0045] According to an embodiment, the invention is further characterized by an electrical interface extending from the circuit board and extending to the electrical connector, wherein the electrical interface (i) establishes an electrical connection between the circuit board and the electrical connector, and (ii) operates to physically secure the circuit board to the housing and fix the position of the circuit board.

[0046] According to an embodiment, the invention is further characterized by a controller programmed to operate the actuator to adjust the position of the image sensor relative to the circuit board to align the image sensor with the focal plane.

[0047] According to an embodiment, the desired position of the image sensor relative to the circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) in response to the initiation of a power cycle and the image sensor not being in the desired position, operate the actuator to reposition the image sensor to the desired position.

[0048] According to an embodiment, the desired position of the image sensor relative to the circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) update the desired position of the image sensor and operate the actuator to reposition the image sensor to the updated desired position in response to a change in the desired position.

[0049] According to an embodiment, the actuator is configured to linearly translate the image sensor relative to the circuit board.

[0050] According to an embodiment, the actuator is configured to rotate the image sensor relative to the circuit board.

[0051] According to the present invention, a method for manufacturing a vision sensor having a lens, a circuit board, and an image sensor, the method comprising: fixing the lens to a base structure of the vision sensor; fixing the circuit board to the base structure and relative to the lens; attaching the image sensor to the circuit board via at least one actuator; and adjusting the position of the image sensor relative to the circuit board via the at least one actuator to align the image sensor with a focal plane defined by the lens.

[0052] In one aspect of the invention, the method includes storing a desired position of the image sensor relative to the circuit board, wherein the desired position corresponds to the alignment of the image sensor with the focal plane.

[0053] In one aspect of the invention, the method includes updating the stored desired position of the image sensor in response to a change in the desired position.

[0054] In one aspect of the invention, the method includes operating the actuator to reposition the image sensor to the updated desired location in response to updating the stored desired location of the image sensor.

[0055] In one aspect of the invention, adjusting the position of the image sensor includes linearly translating the image sensor relative to the circuit board.

[0056] In one aspect of the invention, adjusting the position of the image sensor includes rotating the image sensor relative to the circuit board.

Claims

1. A vision system for a vehicle, comprising: A housing that defines an internal cavity, a first opening providing access to the internal cavity, and a second opening providing access to the internal cavity; A lens, which is fixed to the housing, disposed within the first aperture, and defines a focal plane within the internal cavity; A printed circuit board disposed within the internal cavity; An electrical connector, which is fixed to the housing and is externally disposed on the opposite side of the second opening relative to the internal cavity; An electrical interface extends from the printed circuit board through the second aperture and reaches the electrical connector, wherein the electrical interface establishes an electrical connection between the printed circuit board and the electrical connector, is fixed to the housing within the second aperture, and fixes the position of the printed circuit board within the internal cavity; An image sensor, wherein the image sensor is disposed within the internal cavity and is electrically connected to the printed circuit board; as well as An actuator is disposed on the printed circuit board and configured to adjust the position of the image sensor relative to the printed circuit board to align the image sensor with the focal plane.

2. The vision system of claim 1, further comprising a controller programmed to operate the actuator to adjust the position of the image sensor relative to the printed circuit board to align the image sensor with the focal plane.

3. The vision system of claim 2, wherein the desired position of the image sensor relative to the printed circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) in response to the initiation of a power cycle and the image sensor not being in the desired position, operate the actuator to reposition the image sensor to the desired position.

4. The vision system of claim 2, wherein the desired position of the image sensor relative to the printed circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) update the desired position of the image sensor and operate the actuator to reposition the image sensor to the updated desired position in response to a change in the desired position.

5. The vision system of claim 1, wherein the actuator is configured to linearly translate the image sensor relative to the printed circuit board.

6. The vision system of claim 1, wherein the actuator is configured to rotate the image sensor relative to the printed circuit board.

7. A vision sensor, comprising: A housing that defines an internal cavity and an opening that provides access to the internal cavity; A lens is disposed within the aperture and fixed to the housing, such that the position of the lens is fixed relative to the housing, and a focal plane is defined within the internal cavity; A circuit board, wherein the circuit board is disposed within the internal cavity and fixed to the housing, such that the position of the circuit board is fixed relative to the housing and relative to the lens; An image sensor, wherein the image sensor is disposed within the internal cavity and connected to the circuit board; as well as An actuator configured to adjust the position of the image sensor relative to the circuit board to align the image sensor with the focal plane.

8. The vision sensor of claim 7, further comprising an electrical connector fixed to the housing and disposed externally on an opposite side of the housing relative to the internal cavity.

9. The vision sensor of claim 8, further comprising an electrical interface extending from the circuit board and extending to the electrical connector, wherein the electrical interface (i) establishes an electrical connection between the circuit board and the electrical connector, and (ii) operates to physically secure the circuit board to the housing and fix the position of the circuit board.

10. The vision sensor of claim 7, further comprising a controller programmed to operate the actuator to adjust the position of the image sensor relative to the circuit board to align the image sensor with the focal plane.

11. The vision sensor of claim 10, wherein the desired position of the image sensor relative to the circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) in response to the initiation of a power cycle and the image sensor not being in the desired position, operate the actuator to reposition the image sensor to the desired position.

12. The vision sensor of claim 10, wherein the desired position of the image sensor relative to the circuit board corresponds to the alignment of the image sensor with the focal plane, and wherein the controller is further programmed to (i) store the desired position of the image sensor, and (ii) update the desired position of the image sensor and operate the actuator to reposition the image sensor to the updated desired position in response to a change in the desired position.

13. The vision sensor of claim 7, wherein the actuator is configured to linearly translate the image sensor relative to the circuit board.

14. The vision sensor of claim 7, wherein the actuator is configured to rotate the image sensor relative to the circuit board.

15. A method of manufacturing a vision sensor, the vision sensor having a lens, a circuit board, and an image sensor, the method comprising: The position of the lens is fixed to the base structure of the vision sensor; The circuit board is fixed to the base structure and relative to the lens; The image sensor is attached to the circuit board via at least one actuator; The position of the image sensor relative to the circuit board is adjusted via the at least one actuator so that the image sensor is aligned with the focal plane defined by the lens; The desired position of the image sensor relative to the circuit board is stored, wherein the desired position corresponds to the alignment of the image sensor with the focal plane; In response to a change in the desired position, the stored desired position of the image sensor is updated; as well as In response to updating the stored desired position of the image sensor, the actuator is operated to reposition the image sensor to the updated desired position.

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