Vehicle sensor calibration and test system

Abstract

A system and method of calibrating a sensor (15) of a vehicle (12) includes providing a plurality of targets (14) for calibrating a sensor (15) on an equipped vehicle (12) of a plurality of vehicle categories, where each vehicle category defines a position of at least one sensor (15) on a vehicle (12) of the vehicle category, the method further includes orienting a vehicle (12) at a reference position on a vehicle platform (22), and moving the vehicle (12) based on a vehicle category of the orientated vehicle to align the plurality of targets (14) with the sensor (15) for calibrating the sensor (15).

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 586,044, filed September 28, 2023, the entire contents of which are incorporated herein by reference.

[0002] Technical Field and Background Technology This invention relates to a vehicle sensor calibration and testing system, and more particularly to a method and system for aligning a vehicle with ADAS sensors with one or more calibration targets for the calibration and / or testing of said sensors.

[0003] Using radar, imaging systems, and other sensors such as LIDAR, ultrasonic, and infrared (IR) sensors to determine the range, speed, and angle (elevation or azimuth) of objects in the environment is important in many automotive safety systems, including Advanced Driver Assistance Systems (ADAS) for vehicles. Conventional ADAS systems utilize one or more sensors. While these sensors are aligned and / or calibrated by the manufacturer during vehicle production, enabling them to provide accurate driver assistance functions, sensors may require periodic realignment or recalibration due to factors such as wear and tear, or misalignment caused by driving conditions or accidents such as collisions. However, given the wide range of vehicle body types and sizes, and the different locations of sensors on each vehicle, multiple setups are required for each vehicle. Furthermore, in the case of autonomous vehicles, the number of sensors can vary significantly—autonomous vehicles have a large number of sensors and require a greater number of setups than conventional vehicles. Additionally, considering that many of their sensors control the driving of the car, they may require calibration more frequently than in conventional vehicles. Summary of the Invention

[0004] This disclosure provides a method and system for calibrating and / or testing vehicle sensors using multiple calibration targets, said calibration targets being arranged and positioned for calibrating and / or testing one or more sensors of a specified vehicle among a variety of different vehicles.

[0005] The system provides multiple calibration targets, which may be fixed or movable, for example, in a vehicle station. In one embodiment, the vehicle is positioned on a vehicle alignment system that places the vehicle in a known position for the calibration and / or testing of vehicle sensors, such as ADAS sensors. The system may also include a vehicle turntable on which the alignment system is disposed. Depending on the vehicle under test, the turntable can rotate the vehicle after alignment, thereby orienting the vehicle relative to a target suitable for the vehicle under test. Thus, the multiple targets may include targets for vehicles of various manufacturers, models, and years, wherein the system is operable to rotate the vehicle under test to an orientation relative to a target suitable for calibrating or testing its sensors, thereby configuring the system to adapt to multiple vehicles by manufacturer and / or model. In another embodiment, the multiple targets may move around the vehicle positioned in a known orientation to position an appropriate target relative to the vehicle under test. These targets may also include targets for various manufacturers, models, and / or years, wherein these targets move to align with the coordinate systems of the sensors and the vehicle under test. In any implementation, the system can be configured to include a Dynamic Vehicle Test (DVT) bench for dynamic sensor calibration and / or testing. In a particular implementation, the DVT bench includes a roller brake that can be integrated into a turntable. Furthermore, a vehicle alignment system with DVT can be employed. In such an implementation, a positioning arm can extend inward from around the vehicle to contact and align it on the test bench, or the positioning arm can extend outward from under the vehicle.

[0006] In one embodiment, a method for calibrating sensors on a vehicle having a vehicle category, wherein the vehicle category defines the location of the sensors on the vehicle. The method includes providing a plurality of calibration targets and positioning the calibration targets in reference target locations based on the vehicle category. The method further includes positioning the vehicle in a known reference vehicle location such that when the vehicle is in the known reference vehicle location, the calibration targets are aligned with the vehicle's sensors.

[0007] In another embodiment, a method for calibrating sensors on multiple different vehicles includes providing a plurality of calibration targets. A first vehicle equipped with sensors is aligned and positioned in a first known reference vehicle location relative to a first set of calibration targets, such that the sensors of the first vehicle are aligned with the first set of calibration targets to calibrate the sensors of the first vehicle. A second vehicle equipped with sensors is aligned and positioned in a second known reference vehicle location relative to a second set of calibration targets, such that the sensors of the second vehicle are aligned with the second set of calibration targets to calibrate the sensors of the second vehicle.

[0008] In any of the above methods, the first vehicle and the second vehicle may be vehicles of different categories, such as different types of vehicles, different brands of vehicles, and / or different models of vehicles.

[0009] In one aspect, the plurality of calibration targets may be located at known fixed target positions, and a corresponding vehicle in the first and second vehicles may move to its corresponding known reference vehicle position such that its sensor is aligned with its respective set of calibration targets. The vehicle may be moved relative to the target via a turntable, where the target may be fixed. In another aspect, the corresponding vehicle first moves to a known initial vehicle position, and then from its known initial vehicle position to its corresponding known reference vehicle position. The vehicle may be moved, for example, by rotating the vehicle on a vehicle turntable.

[0010] Alternatively, each corresponding vehicle may have a fixed, known reference vehicle position, and a corresponding set of calibration targets from the first and second sets of calibration targets may be moved to the known reference target position to align and position the corresponding calibration target with the sensors on the vehicle for alignment of the sensors of the corresponding vehicle. For example, the calibration targets may be moved by a robotic arm.

[0011] In any method, the coordinates of the known reference vehicle position for each vehicle are referenced to components of the reference vehicle, such as the center of the front axle of the reference vehicle.

[0012] Furthermore, after aligning the first vehicle with and positioning it relative to the first set of calibration targets at the position of the first known reference vehicle, the first set of calibration targets calibrates the sensors of the first vehicle. Similarly, after removing the first vehicle from the system and aligning and positioning the second vehicle with and positioning it relative to the second set of calibration targets at the position of the second known reference vehicle, the second set of calibration targets calibrates the sensors of the second vehicle.

[0013] In any of the above methods, the first vehicle and the second vehicle may be vehicles of different categories, such as different types of vehicles, different brands of vehicles, and / or different models of vehicles.

[0014] According to another embodiment, a vehicle testing and calibration system for calibrating sensors on a vehicle includes a target positioning system and a vehicle station for receiving a vehicle equipped with sensors. The vehicle has a vehicle category associated with it, which defines the location of the sensors on the vehicle; and a known reference vehicle location. The target positioning system includes a plurality of calibration targets arranged in a defined space at known fixed target locations based on the vehicle's vehicle category, such that when the vehicle is located at the known reference vehicle location in the vehicle station, the calibration targets are aligned with the vehicle's sensors.

[0015] According to another embodiment, a system for dynamically calibrating sensors on a vehicle includes a target positioning system and a vehicle station for receiving a vehicle equipped with sensors. The target positioning system includes a plurality of calibration targets arranged within a defined space at known fixed target positions. The vehicle station is configured to receive the vehicle at a known initial vehicle position within the vehicle station. The system further includes a computer system configured to determine the known reference vehicle position associated with the vehicle and then selectively control movement of the vehicle within the vehicle station toward the known reference vehicle position, such that the vehicle's sensors are aligned with at least a first set of calibration targets, wherein the first set of calibration targets is operable to calibrate the vehicle's sensors.

[0016] According to another embodiment, a system for dynamically calibrating sensors located on multiple different vehicles includes a target positioning system and a vehicle station for receiving vehicles equipped with sensors. The calibration target positioning system includes a plurality of calibration targets arranged in a defined space at known fixed target positions. The vehicle station is configured to receive a vehicle at a known initial vehicle position within the vehicle station. The system also includes a computer system configured to determine the known reference vehicle position associated with the vehicle, and then selectively control the movement of the vehicle within the vehicle station and move the vehicle to the known reference vehicle position, thereby aligning the vehicle's sensors with a first set of calibration targets, wherein the first set of calibration targets is operable to calibrate the vehicle's sensors.

[0017] In another aspect, the vehicle station is configured to receive a second vehicle, and is also configured to receive the second vehicle at the known initial position. The computer system is configured to determine a second known reference vehicle position associated with the second vehicle, and then selectively control the movement of the second vehicle in the vehicle station toward the second known reference position, such that the sensors of the second vehicle are aligned with a second set of calibration targets, wherein the second set of calibration targets is operable to calibrate the sensors of the second vehicle.

[0018] In another aspect, the vehicle station has a vehicle turntable, which is controlled by the control system to rotate the corresponding vehicle from the known initial position to the corresponding known reference vehicle position.

[0019] According to another embodiment, a system for dynamically calibrating sensors on multiple different vehicles includes a target positioning system and a vehicle station for receiving vehicles equipped with sensors. The target positioning system includes a plurality of calibration targets arranged within a defined space. The vehicle station is configured to receive a vehicle at a known reference vehicle location. The system also includes a computer system storing a plurality of vehicle categories and a reference target location associated with each calibration target for each vehicle category. The computer system is configured to determine the vehicle category of a vehicle located at the known vehicle location in the vehicle station and to control the calibration target positioning system to move at least one set of calibration targets from the plurality of calibration targets to the reference target location associated with the vehicle category of the vehicle, such that the set of calibration targets is aligned with the vehicle's sensors and operable to calibrate the vehicle's sensors.

[0020] In one aspect, the vehicle station is configured to receive a second vehicle (after the first vehicle has left the vehicle station), and the vehicle station is also configured to receive the second vehicle at the known reference location. The computer system is further configured to control the target positioning system to move a second set of calibration targets from the plurality of calibration targets to a reference target location associated with the vehicle category of the second vehicle, such that the second set of calibration targets is aligned with the sensors of the second vehicle and is operable to calibrate the sensors of the second vehicle. For example, the calibration targets may be moved by a robotic arm to their respective known reference target locations.

[0021] In any of the above systems, the coordinates of the known reference vehicle position for each vehicle are associated with a component of the reference vehicle, such as the center of the front axle of the reference vehicle.

[0022] This invention provides a system and method for precisely positioning a vehicle with sensors relative to a set of calibration targets to suit various vehicles and calibrating the sensors according to, for example, OEM specifications. This dynamic system and method provides rapid and accurate calibration of sensors for various vehicles. These and other objects, advantages, objectives, and features of the invention will become apparent from a review of the following description taken in conjunction with the accompanying drawings. Attached Figure Description

[0023] Figure 1 It is a 3D view of a dynamic vehicle testing and calibration system; Figure 2A yes Figure 1 An enlarged 3D view of the vehicle platform for the vehicle testing and calibration system; Figure 2B yes Figure 1 A top view of the vehicle centering system of the target alignment system; Figure 2C yes Figure 2B A three-dimensional diagram of the vehicle centering system; Figure 2D yes Figure 2B A side perspective perspective view of the front wheel assembly support of the vehicle centering system; Figure 2E yes Figure 2B A bottom view of the front wheel assembly support of the vehicle centering system; Figure 2F yes Figure 2B A bottom view of the rear wheel assembly support of the vehicle centering system; Figure 3 yes Figure 1 A perspective view of another embodiment of the vehicle platform for the vehicle testing and calibration system; and Figure 4 yes Figure 4 Side view of the vehicle platform. Detailed Implementation

[0024] This disclosure will now be described with reference to the accompanying drawings, wherein the numbered elements in the following written description correspond to the similarly numbered elements in the drawings.

[0025] refer to Figure 1The number 10 generally represents a vehicle testing and calibration system configured to calibrate multiple sensors on vehicle 12 (Figure 2) using calibration targets 14. These sensors may include cameras, such as front-view cameras, rear-view cameras, side-view cameras, surround-view camera systems, or may include radar sensors, lidar sensors, sonar / ultrasonic sensors, etc. Calibration targets 14 are constructed for the calibration and / or testing of sensors, such as according to OEM specifications. The vehicle may be a conventional vehicle or an autonomous vehicle, with autonomous vehicles often having more sensors than conventional vehicles. As will be described more fully below, each calibration target 14 is positioned relative to a known reference vehicle position of vehicle 12 so that it aligns with the sensors of vehicle 12 when the vehicle is positioned and aligned at the known reference vehicle position. Optionally, as a reference... Figure 4 As described in Figure 5, the vehicle testing and calibration system 10 can be combined with other testing equipment, such as dynamic vehicle testing equipment.

[0026] In the illustrated embodiment, the vehicle testing and calibration system 10 includes a calibration target positioning system 16 and a system for receiving signals from one or more sensors 15. Figure 2A Vehicle station 18 of vehicle 12. Vehicle 12 has an associated vehicle identity or category, such as based on vehicle type, such as based on vehicle manufacturer, model and / or year, and / or based on vehicle identification number (VIN), which defines the type and location of sensor 15 of vehicle 12, for example, by referring to a fixed reference point on the vehicle, such as the center of the front axle. The type and location of the target 14 used to calibrate sensor 15 are also based on or defined by vehicle identity. This includes which targets 14 will be used to calibrate a given sensor 15 on vehicle 12, and where such targets 14 should be positioned relative to vehicle 12 to calibrate sensor 15. Although vehicle 12 is illustrated herein as having a single sensor 15, it should be understood that a given vehicle 12 may have multiple sensors 15 mounted at different locations around vehicle 12, and these sensors require different targets 14 for their calibration. Although references to calibration are cited herein, it should also be understood that this system and method can be used for the purpose of verifying the proper functioning of sensor 15 without running an OEM calibration procedure on sensor 15. In this case, calibration serves as a check or verification of the proper functioning of sensor 15.

[0027] Information regarding the sensor 15 and its position on the vehicle 12, and the targets 14 and their positions relative to the vehicle 12 required for the calibration of a given sensor 15, can be stored in a computer system based on the vehicle identity, as described below. This information can also be used as a reference to determine when a vehicle is in its known reference vehicle position and to determine the known reference target position for the initial setup of each calibration target 14 based on the position of the sensor 15 on the vehicle 12. Once the calibration targets 14 are set for a given vehicle identity, they can remain in their known reference target positions. Therefore, once the vehicle identity of the vehicle 12 is known, the position of the sensor 15 on the vehicle 12 is known. Furthermore, once the vehicle 12 is aligned and positioned in its known reference vehicle position, the position of the sensor 15 is aligned with their respective calibration targets 14 for that given vehicle 12.

[0028] Therefore, in the illustrated embodiment, the calibration target positioning system 16 includes a plurality of calibration targets 14, which are arranged at known fixed target positions within a defined space relative to the vehicle station 18, and particularly relative to the vehicle support platform 22, based on the vehicle identity or category of the vehicle 12. Thus, when the vehicle 12 moves to its known reference vehicle position in the vehicle station 18, the known fixed target position aligns with the sensor 15 of the vehicle 12.

[0029] In the illustrated embodiment, and from Figure 1 Best understood, calibration targets 14 can be arranged around a virtual dome or virtual hemispherical space around the vehicle bay and thus relative to the corresponding vehicle 12. The virtual dome can thus provide a Cartesian coordinate system in which targets 14 are located at reference target positions for the sensors 15 of the vehicle 12. Specifically, system 10 includes a plurality of targets 14, a subset of which is used to calibrate sensors on a specific vehicle based on vehicle identity. For example, some targets 14a can be used to calibrate sensors on a 2017 Subaru Forester, while other targets 14b can be used to calibrate sensors on a 2016 Nissan X-Trail. As discussed in more detail below, a given vehicle 12 positioned on vehicle support platform 22 can be moved by movement of platform 22 to achieve the correct orientation for calibrating its sensors 15.

[0030] When the corresponding calibration target 14 is positioned relative to the vehicle 12 and aligned with the sensors of the vehicle 12, a calibration routine is executed, thereby calibrating the sensor using the corresponding calibration target. This may include running a calibration procedure and / or performing calibration tests on the sensor 15 to confirm its proper functioning.

[0031] refer to Figure 2AVehicle bay 18 includes a vehicle support platform 22 with an alignment system 24 having a front wheel support and alignment assembly 24a and a rear wheel support and alignment assembly 24b, on which vehicle 12 is positioned for positioning or orientation within vehicle bay 18. Alignment system 24 can be configured to provide “inside-out” alignment, where wheels are pushed outward from their inward-facing sides, or “outside-in” alignment, where wheels are pushed inward from their outward-facing sides. For details regarding suitable alignment systems, refer to U.S. Patent No. 11,597,091, jointly owned by BPG Sales and Technology, the entire contents of which are incorporated herein by reference for aligning a vehicle in a vehicle bay. Furthermore, vehicle bay 18 may utilize non-contact wheel alignment sensors to assist in the alignment of vehicle 12 within vehicle bay 18, as described in the cited disclosure.

[0032] refer to Figures 2A to 2E The front wheel support and centering assembly 24a includes opposing tire supports 64a and 64b, which are positioned on opposite sides of the front vehicle centering device 66. The tire supports 64a and 64b are configured to receive a pair of opposing tires and wheel assemblies of the vehicle 12, such as... Figure 2A The front tire and wheel assembly 12a is shown (one is shown). Tire supports 64a and 64b are substantially identical, but are mirror images of each other. Therefore, the discussion herein focuses on tire support 64a, but it should be understood that the discussion also applies to tire support 64b.

[0033] The tire support 64a includes two sets of rollers 72, 68 and 70, wherein the rollers 72 are arranged such that their axes of rotation are parallel to the longitudinal axis of the vehicle 12 when it is mounted on the support platform 22. Thus, a vehicle with a pair of front tires mounted on the rollers 72 can move laterally relative to its longitudinal axis via the rollers 72. Figure 2C and Figure 2D As best shown, the two sets of rollers 72, 68 and 70, are angled inward relative to each other. That is, the adjacent positioning ends of the rollers 72 in each set of 68 and 70 are set lower vertically than the outward positioning ends, forming a V-shape. Thus, when the wheel assembly 12a of the vehicle 12 is positioned on the tire supports 64a and 64b, it will naturally be oriented to rest in a fixed longitudinal position along the axes 74a and 74b defined by the adjacent mounting ends of the rollers 72. It should be understood that the axes 74a and 74b are arranged to be aligned with each other and perpendicular to the track 48, and perpendicular to the longitudinal axis of the vehicle 12 when positioned on the platform 22. The tire support 64a additionally includes ramps 76 and 78 for supporting the vehicle tires when the vehicle 34 drives onto or off the support platform 22.

[0034] Vehicle 12 is partially centered or positioned on support platform 22 via vehicle centering device 66, which is operable to center or position the front portion of vehicle 12. Vehicle centering device 66 includes a pair of opposing synchronized arms or push plates 80a, 80b configured to extend outward from housing 82 to contact the inner sidewalls of tires mounted on tire supports 64a, 64b. Specifically, arms 80a, 80b are connected via a pair of actuators 84a, 84b (… Figure 2E The actuators move synchronously and equally outward from the housing 82 in opposite directions, and are connected and operated by a controller 40. Figure 2D and Figure 2E It is understood that arm 84a is fixed to or is part of plate 86a, and arm 84b is fixed to or is part of plate 86b, with plates 86a and 86b slidably mounted on guide rails or slide rails 88 and 90. An extendable end 92a of actuator 84a is mounted to plate 86a, thereby extending arm 84a outward. Similarly, an extendable end 92b of actuator 84b is mounted to plate 86b, thereby extending arm 84b outward. Arms 80a and 80b can also be retracted via the retraction of ends 92a and 92b of actuators 84a and 84b. Therefore, it should be understood that the vehicle centering device 66 is operable to allow the vehicle to move laterally via the equal and opposite extensions of the arms 80a and 80b through the rollers 72, so that the arms 80a and 80b contact and push against the inner sidewall of the tire, thereby centering the front portion of the vehicle 12 on the vehicle support platform 22.

[0035] refer to Figure 2B , Figure 2C and Figure 2F The rear wheel support and centering assembly 24b includes opposing tire supports 94a and 94b positioned on opposite sides of the rear vehicle centering device 96, wherein the tire supports 94a and 94b are configured to receive a pair of opposing tires and wheel assemblies of the vehicle 12, such as... Figure 2A The rear wheel assembly 12b is shown (one is shown). Tire supports 94a and 94b are substantially identical, but are mirror images of each other. Therefore, the discussion herein focuses on tire support 94a, but it should be understood that the discussion also applies to tire support 94b.

[0036] In the illustrated embodiment, the tire support 94a includes six sets of rollers 100, 98a to 98f, wherein the rollers 100 are arranged such that their axis of rotation is parallel to the longitudinal axis of the vehicle 12 when it is mounted on the support platform 22. This allows a vehicle with a pair of rear tires positioned on the rollers 100 to move laterally relative to its longitudinal axis via the rollers 100. Compared to the front wheel supports and centering assembly 24a, the rollers 100 of the rear wheel supports and centering assembly 24b are all located in the same plane. The multiple sets of rollers 100 98a to 98f allow vehicles with different wheelbases to be used on the support platform 22. That is, for example, when the opposing front wheel assemblies of a vehicle are secured by the tire supports 64a, 64b, the opposing rear wheel assemblies of the vehicle can still be positioned on the tire supports 94a, 94b even if the wheelbase lengths of the vehicles are different. Ramps may also be provided at the entrances and exits of the tire supports 94a, 94b to assist vehicles in driving onto and off the supports.

[0037] Vehicle 12 is also partially centered or positioned on support platform 22 via rear vehicle centering device 96, which operates in a manner generally similar to vehicle centering device 66 to center or position the rear portion of vehicle 12. Rear vehicle centering device 96 includes multiple pairs of opposing and synchronized positioning arms or push plates 102a, 102b, 104a, 104b and 106a, 106b, configured to extend outward from housing 108 to contact the inner sidewalls of tires disposed on tire supports 94a, 94b. Specifically, each pair of opposing arms of centering device 96 moves synchronously and equally outward from housing 108 in opposite directions via actuators 110, 112, 114, 116 (FIG. 7), which are connected together and operated by controller 40. Arms 102a, 102b, 104a, 104b, 106a, and 106b are slidably mounted on guide rails or slide rails 118, 120, 122, and 124 for movement, whereby the movable ends 110a, 112a, 114a, and 116a of actuators 110, 112, 114, and 116a can extend and retract arms 102a, 102b, 104a, 104b, 106a, and 106b relative to housing 108, including via pulley linkages 126 and 128. Therefore, it should be understood that the vehicle centering device 96 is operable to allow the vehicle to move laterally via the equal and opposite extensions of the arms 102a, 102b, 104a, 104b, 106a and 106b through the rollers 100, thereby causing the arms to contact and push against the inner sidewall of the tire, thereby centering the rear portion of the vehicle 12 on the vehicle support platform 22.

[0038] Although in the illustrated embodiment, the vehicle support platform 22 positions, centers, and / or orients the vehicle 12 by pushing against the inner sidewall of the tire with an arm, it should be readily understood that the constructed centering system can be alternatively constructed in which an arm or pusher, such as an inwardly extending positioning arm, presses against the outer sidewall of the tire by pushing inward from the outside of the vehicle with equal and opposite amounts. Furthermore, although the tire supports 64a, 64b and 94a, 94b of system 10 are disclosed as utilizing rollers 72, 100 for lateral adjustment of the vehicle 12 on the support platform 22, it should be understood that alternative tire supports can be employed within the scope of the invention. For example, the tire support can be constructed as a floating clamp, such as a conventional floating plate or a floating type plate. Such a floating plate assembly can be recessed into the vehicle support platform and configured to allow the vehicle wheel assembly to float freely on the plate in multiple degrees of freedom, including lateral floating relative to the vehicle's longitudinal axis.

[0039] Optionally, the vehicle platform 22 includes a pair of ramps 22a to guide the vehicle 12 onto wheel supports and centering components 24a, 24b.

[0040] In addition, fastening devices such as wheel stops, clamps, or chains (such as references) can be installed in vehicle bay 18. Figure 4 As described, this secures the vehicle 12 to the support platform 22 in the vehicle station 18. This ensures the vehicle remains stable when the centering system is deployed.

[0041] Refer again Figure 1 As described above, the vehicle testing and calibration system 10 includes a calibration target positioning system 16 and a vehicle station 18, both controlled by a computer system or controller 19 configured to control alignment and orientation functions, perform calibration procedures, and other functions described below. As discussed in more detail below, the computer system 19 may include or contain a controller, such as a microprocessor-based controller, and memory for processing instructions or algorithms stored in the memory to control the operation of the calibration target positioning system and the vehicle station. The controller may include one or more microcontrollers, field-programmable gate arrays, systems-on-a-chip, discrete circuitry, and / or other suitable hardware, software, or firmware capable of performing the described functions. In one embodiment, the controller may be configured as a programmable logic controller (PLC) of system 10.

[0042] Computer system 19 is configured to acquire vehicle data associated with the vehicle identity of vehicle 12, control alignment system 24, and further detect when the vehicle is aligned and positioned at its known reference vehicle location. For example, the control system may include sensors, such as distance sensors, including distance sensors configured as time-of-flight (“ToF”) sensors and mounted on vehicle platform 18, to detect when the vehicle is at its known reference vehicle location. Control system 19 may include a user interface where an operator can input the manufacturer, model, and year of vehicle 12 and / or VIN, or control system 19 may be configured to automatically detect the vehicle identity of vehicle 12, such as via a vision system integrated with control system 19 or via an electronic data link with vehicle 12, or an operator may use a device to scan or read data from vehicle 12 into control system 19.

[0043] In the initial vehicle setup step, vehicle 12 enters vehicle bay 18 and is driven onto vehicle platform 22, thereby positioning itself on centering device 24. Vehicle 12 can be driven into vehicle bay 18 by an operator, or, in the case of an autonomous vehicle, can be driven autonomously. Vehicle information is acquired to establish vehicle identity; this information can be entered into computer system 19 by the operator or acquired by computer system 19 as described above. Vehicle 12 can also be secured to platform 22, such as via wheel chocks, or fixed to the platform. Vehicle 12 can be centered on the vehicle platform.

[0044] As described above, the vehicle testing and calibration system 10 can be used to calibrate more than one type of vehicle 12, wherein the vehicles 12 have different vehicle categories or identities, causing sensor types and / or sensor positions to vary among the vehicles 12. As described above and more fully below, calibration targets 14 can be fixed and located at known fixed target locations, and further, can be grouped, such as 14a, 14b, where one group is used to align and calibrate sensors on vehicles of one vehicle category, and another group is used to align and calibrate sensors on another vehicle of a different vehicle category, such that the groups of calibration targets can be customized to accommodate different sensor arrangements without moving the calibration targets. Thus, the vehicle 12 can be moved within the station 18 to align the vehicle 12, thereby aligning and / or moving its accompanying sensors 15 to the relevant targets 14, such as aligning a specific group of targets 14a or 14b based on the specific vehicle identity of the vehicle 12 on the support platform 22.

[0045] In the illustrated embodiment, to move vehicle 12 in vehicle bay 18, platform 22 may include turntable 30 supporting alignment system 24 and used to position vehicle 12 to a specific vehicle position or orientation by rotating vehicle 12, such as from a known initial vehicle position or orientation in vehicle bay 18—the position where vehicle 12 is first aligned in the bay—to a second orientation that aligns its sensors 15 with calibration targets 14 of a specific set 14a or 14b arranged for the sensors 15 of that vehicle 12. It should be understood that system 10 may include multiple sets of targets for calibrating sensors on vehicles from multiple different vehicle categories. Each target set 14a, 14b may include one or more targets for calibrating one or more sensors 15 on a given vehicle 12. Therefore, turntable 30 may be able to operate in pairs to position vehicles to multiple different vehicle orientations by rotation, such as based on vehicle category or identity, in which the sensors 15 of that vehicle 12 are aligned with the relevant target set 14 to calibrate those sensors 15. It should be understood that, for at least one vehicle category, the known initial vehicle position or orientation may coincide with the target group of that vehicle without needing to locate the vehicle by rotating the turntable 30. That is, when the turntable 30 is in its initial orientation as when the vehicle 12 is driven onto the platform 22.

[0046] In this embodiment, the control system 19 can also control the turntable 30. Based on the acquired data of the vehicle 12, the control system 19 adjusts the orientation of the turntable 19 to position the vehicle 12 supported thereon in a vehicle orientation, thereby aligning the sensors 15 of the vehicle 12 with a set of calibration targets 14 positioned for that vehicle 12. It should be understood that in each vehicle orientation, a Cartesian coordinate system with coordinates (0, 0, 0) centered at a fixed reference point, such as the front axle of the vehicle 12, is established, in which a set of targets 14 (such as target 14a) is positioned relative to this coordinate system for calibrating the sensors 15 on the vehicle 12. For vehicles from different vehicle categories or identities, the turntable 30 rotates to another vehicle orientation, in which a Cartesian coordinate system with coordinates (0, 0, 0) centered at the fixed reference point (e.g., the front axle) of that other vehicle orientation is established, in which a set of targets 14 (such as target 14b) is positioned relative to this coordinate system for calibrating the sensors 15 on that alternative vehicle 12. This is established for each vehicle category. Therefore, when a vehicle from a given vehicle category is positioned on platform 22, turntable 30 rotates the vehicle to the associated vehicle orientation to align with the target for calibrating the sensors on that vehicle.

[0047] For example, for vehicles of category A, turntable 30 can be moved to a position A degrees from the top dead center, where the top dead center can refer to the initial orientation of turntable 30 when the vehicle is driven onto platform 22. In this vehicle orientation, all calibration targets for category A vehicles are positioned for calibrating sensors on category A vehicles. For vehicles of category B, the turntable can be selectively moved to a position B degrees from the top dead center, where all calibration targets for category B vehicles are positioned for calibrating sensors on category B vehicles. It should be understood that multiple vehicle orientation positions can exist during a 360-degree rotation of turntable 30, limited only by the space available for setting the target 14 around it. For this purpose, the target 14 can be supported on or by a frame or platform within station 18.

[0048] Optionally, the turntable may have an angle—or vehicle orientation position—designated as a “flexible station” with a set of robots configured to position one or more calibration targets in place, such as for custom setups. In this way, the test and calibration system 10 is an automated multi-OEM calibration system with high speed and accuracy, and is fully upgradeable for future sensor additions. While the foregoing discussion of calibrating vehicle sensors on a vehicle at a single vehicle orientation position based on vehicle category is relevant, it should be understood that in alternative configurations, a given vehicle can be rotated to different positions to align with different targets used to calibrate different sensors. For example, a forward-looking camera can be calibrated at one position on turntable 30, where turntable 30 is rotated to orient the vehicle to different orientations to align with targets used to calibrate different sensors on the vehicle.

[0049] Once the vehicle setup is complete—that is, once the vehicle has been centered on support platform 22 and rotated to vehicle orientation via turntable 30—control system 19 is then configured to perform a calibration process. Specifically, once computer system 19 detects that vehicle 12 is aligned and positioned in its known reference vehicle position, the computer initiates the calibration process, provided that the vehicle is aligned and positioned in its known reference vehicle position and calibration target 14 is positioned in its known reference target position (and thus aligned with the corresponding sensor 15 of vehicle 12). Calibration of sensor 15, such as according to OEM specifications, can then be performed.

[0050] To this end, a series of instructions for performing the calibration process can be provided to the operator via a user interface of the computer system 19, such as a graphical user interface (“GUI”). These instructions can be based on a flowchart that requests information from the operator about the vehicle, such as manufacturer, model, year, VIN, and / or details about the vehicle equipment, such as tires and wheel size, vehicle option types (including sensor options), and also provides the operator with information about the system and the vehicle settings used for sensor calibration.

[0051] As will be described more fully below with reference to another embodiment, alternatively, once the vehicle is aligned and positioned at a known reference vehicle location, the calibration target positioning system can be configured to move at least one set of calibration targets to align with the vehicle's sensors. For example, all or selected calibration targets 14 can be moved within station 18 using, for example, a robotic arm. Furthermore, movable calibration targets 14 can be moved within station 18 to calibrate sensors on vehicles with different sensor configurations. Calibration targets can be moved, either in place of vehicle movement or in combination with vehicle movement. The calibration target positioning system can be configured to move a second set of calibration targets to align with sensors on a second vehicle. Additionally, some calibration targets can be fixed calibration targets located at fixed known target positions, while others can be movable and moved to known reference target positions associated with each vehicle of a different vehicle category to accommodate different sensor positions on different vehicles. Further details are provided in the embodiments described below.

[0052] In such an implementation, the vehicle testing and calibration system includes a calibration target positioning system and a vehicle station for calibrating more than one vehicle, specifically vehicles with different vehicle categories that cause sensor positions to vary between vehicles.

[0053] In this embodiment, the vehicle station receives vehicles and similarly includes a platform containing an alignment system, such as the alignment system 24 described above, to align vehicle 12 within the vehicle station and position vehicle 12 at a known reference vehicle position within the vehicle station. For this purpose, the vehicle station includes multiple robots configured to hold and position various targets. These robots include robots with fixed bases and multi-axis arms that can position a corresponding target to a calibration position for a given sensor 15 on vehicle 12. Preferably, when on the platform, the robots are positioned around multiple sides of vehicle 12, such as the front, rear, and at least two of the left and right sides of vehicle 12. Preferably, the robot's base is fixed to the floor. Alternatively, the base can be fixed to different supports, such as overhead or vertical structures. In particular, the robots are capable of grasping targets specific to a given sensor 15 of vehicle 12 and positioning the targets in the correct spatial orientation relative to vehicle 12 based on the vehicle's known position on the alignment system. It should be understood that multiple targets can be located or stored near the respective robot, wherein the robot includes end effectors or tools configured to selectively grasp specific targets required by the sensors 15 of the vehicle under test 12 for calibration.

[0054] The vehicle station may also alternatively or additionally use sensors to facilitate the alignment of vehicle 12 in the vehicle station, such as non-contact wheel alignment sensors, as described in the patents cited above. Furthermore, similar to vehicle station 18, the vehicle station may include fastening devices, such as wheel clamps or wheel stops, to secure vehicle 12 in the vehicle station. For further details, refer to the first embodiment described above.

[0055] As discussed in more detail below, this alternative system includes a computer system, similar to computer system 19 described above, which is also configured to acquire vehicle data to identify or establish the vehicle category of vehicle 12 located in the vehicle bay. Once vehicle 12 is aligned and positioned in its known reference vehicle position in the vehicle bay via an alignment device, calibration target 14 used in conjunction with vehicle 12 is moved to the known reference target position associated with the vehicle (and thus aligned with the corresponding sensor of the vehicle), enabling sensor calibration, such as according to OEM specifications, to be performed.

[0056] Furthermore, the calibration target positioning system can move only one set of calibration targets based on the vehicle category of vehicle 12, so that once vehicle 12 is aligned and positioned at its known reference vehicle position in the vehicle station, the set of calibration targets is aligned with the vehicle's sensors 15.

[0057] Therefore, based on the vehicle category, the calibration target is moved to a known reference target position to align with the vehicle's sensors. After aligning the selected calibration target relative to vehicle 12 and thus with the vehicle 12's sensors, a calibration routine is executed, thereby calibrating the sensors using the appropriate calibration target.

[0058] Alternatively, some calibration targets can be fixed at known fixed target locations, while other calibration targets 114 can be movable.

[0059] In this embodiment, the movable calibration target can be mounted on the robot's arm. The actuators of the robot arm can be controlled by an onboard controller, which in turn is controlled by a control system, or can be directly controlled by the control system. It should be understood that alternative arrangements for moving the respective calibration targets can be used. For example, one or more calibration targets can be mounted on a frame fixed to the floor, wherein the frame has one or more joint members controlled by one or more actuators to move the respective calibration target. Again, the actuators can be controlled by an onboard controller, which in turn is controlled by a control system, or can be directly controlled by the control system. For example, referring to U.S. Patent No. 11,624,608, which is incorporated herein by reference, instead of using a movable base, multiple frames fixed to the floor can be arranged around a vehicle platform, wherein the frames include movable target holders movable on three axes and rotatable about a vertical axis.

[0060] In the initial vehicle setup step, vehicle 12 can be moved into the vehicle bay by a driver, or it can be moved automatically (e.g., when the vehicle is an autonomous vehicle). Once the vehicle is at least in the bay, vehicle category information can be determined by the control system, or input by the operator into the control system, such as by inputting into a desktop computer, laptop, or tablet, or it can be obtained directly from the vehicle 12's computer, such as the vehicle 12's electronic control unit (ECU). For examples of suitable vehicle category information, refer to the preceding implementation.

[0061] Similar to the previous implementation, the fixed reference point on the vehicle is the center of the front axle. Therefore, once the vehicle is aligned in a fixed position, the computer system can use the center of the front axle as the center of a Cartesian coordinate system. The computer system uses this center as the known reference vehicle position for vehicle 12, and thus as the position of sensor 15 on vehicle 12. Furthermore, based on this Cartesian coordinate system and vehicle information, the computer system determines the known reference target positions for that set of calibration targets, and then moves the corresponding targets to the known reference target positions of vehicle 12 located in the vehicle station. Once the vehicle and calibration targets are set up, the control system is configured to execute the calibration process.

[0062] For a discussion of other features and functions that the control system may provide, refer to the above implementation method.

[0063] In any of the systems described above, one or more cameras may be provided to capture images of the vehicle to record the calibration settings of the vehicle and / or target. The images captured by the cameras may be transmitted to the control system, and in some embodiments, may also be used by the control system to establish the appropriate orientation of the calibration target.

[0064] Vehicle sensors can vary and include sensors that are part of one or more subsystems of the vehicle’s Advanced Driver Assistance Systems (ADAS). Thus, sensors can be radar sensors for adaptive cruise control (“ACC”), imaging systems such as camera sensors for lane departure warning (“LDW”) and other ADAS camera sensors positioned around the vehicle, as well as other sensors such as LIDAR, ultrasonic, and infrared (“IR”) sensors for ADAS systems, including sensors mounted inside the vehicle, such as forward-facing cameras, or externally mounted sensors.

[0065] The calibration system can be set up within a repair facility with multiple workstations to calibrate sensors on multiple vehicles—each vehicle workstation is uniquely configured for one category or vehicle, while another workstation is uniquely configured for another category or vehicle. Alternatively, as... Figure 1 As shown, each vehicle workstation can be located within a enclosure with an access door D. Furthermore, the testing and calibration system may include other testing equipment as described below.

[0066] refer to Figure 3 and Figure 4 In any of the systems described above, vehicle platform 22 may include dynamic vehicle testing equipment or platform 324 in place of the centering system 24 described above, optionally including integration with turntable 30, and wherein dynamic vehicle testing equipment 324 may be integrated with an "outside-in" centering system that includes push rods that push the vehicle inward from an outward-facing side to center the vehicle on platform 324. For example, arms or extensions may extend inward from either side of the vehicle toward the vehicle to contact portions, areas, or locations on the vehicle, such as the body, chassis frame, or wheel assembly.

[0067] from Figure 3 and Figure 4It is understood that the dynamic vehicle testing equipment 324 is configured as a rolling brake platform having pairs of rollers 326, 328 that rotatably support the front and rear tires of vehicle 12 and wheel assemblies 12a, 12b. Vehicle 12 is configured to operate on equipment 324 such that the vehicle powertrain drives one or more rollers 326, 328, wherein the rollers 326, 328 can provide rolling resistance to the driven wheels 12a, 12b of vehicle 12 strictly via inertial resistance. Alternatively, an electric motor 330 coupled to the rollers 326, 328 can be used to provide additional resistance to the driven wheels of vehicle 12. While equipment 324 may have four pairs of rollers 326, 328 for each wheel assembly 12a, 12b of vehicle 12, it should be understood that alternative configurations may have fewer such pairs of rollers, such as two front assemblies for a front-wheel-drive vehicle. It should also be understood that alternative configurations and arrangements of roller brake benches or dynamometers may be used. Further details regarding apparatus 324 are referenced to test bench 24 in commonly owned pending U.S. Patent Application Serial No. 18 / 760,366, filed July 1, 2024, the entire contents of which are incorporated herein by reference.

[0068] In this way, vehicle 12 can be dynamically operated on platform 324 as part of a testing and calibration system, such as establishing a Cartesian coordinate system with the front axle center as the origin (0, 0, 0) while establishing a known position of vehicle 12 on platform 324. Specifically, according to this arrangement, the dynamic ADAS system can operate without on-board diagnostic connections such as OBDII connections when the vehicle is in a known position. This can facilitate the testing and calibration of ADAS systems, including systems that might otherwise be inoperable in normal driving settings when diagnostic tools or other equipment are connected to the vehicle's OBD connector port. Furthermore, vehicle 12 can be "steered" on platform 324 for sensor testing or calibration. That is, the steering wheels can rotate, in which case vehicle 12 can be allowed to move longitudinally on platform 324, or alternatively, maintained in the proper position on platform 324 by a centering system. Further, the rollers of platform 324 can be configured to pivot about one or more vertical axes relative to the longitudinal length of platform 324. It should also be understood that stage 324 may be mounted on or as part of a turntable to allow stage 324 to rotate to alternative orientations, such as for testing or calibrating ADAS sensors and systems of alternative manufacturers and / or model vehicles 12, as discussed above.

[0069] Other changes and modifications may be made to the specific embodiments described without departing from the principles of the invention. The scope of the invention is intended to be limited only by the scope of the appended claims, and may be interpreted in accordance with the principles of patent law, including the doctrine of equivalents.

Claims

1. A vehicle testing and calibration system for calibrating sensors on equipped vehicles, the system comprising: At least one calibration target, said at least one calibration target being arranged in a defined space at a known fixed target location; A vehicle platform for receiving a vehicle equipped with at least one sensor, the vehicle having a vehicle category defining the location of the at least one sensor on the vehicle, and the vehicle having a vehicle category reference location associated with the vehicle, wherein the vehicle platform is configured to orient the vehicle to the vehicle category reference location; and The known fixed target location is based on the vehicle category, wherein when the vehicle is oriented at the vehicle category reference location, the at least one calibration target is aligned with the at least one sensor of the vehicle for calibrating the at least one sensor of the vehicle.

2. The system according to claim 1, wherein, The system includes a plurality of targets, each of which is arranged at a known fixed target position within the defined space, and wherein the vehicle platform is configured to individually orient a plurality of vehicles, each having different vehicle categories and each including at least one sensor, to a different vehicle category reference position associated with each vehicle category, and wherein, when a selected vehicle of each vehicle category is oriented to the vehicle category reference position associated with the selected vehicle, at least one of the targets is aligned with at least one sensor on the selected vehicle for calibration of the at least one sensor on the selected vehicle.

3. The vehicle system according to any one of claims 1 or 2, wherein, The vehicle platform includes a turntable rotatable about a vertical axis to rotate vehicles disposed on the vehicle platform, wherein the turntable is configured to rotate to orient each vehicle to an associated vehicle category reference position.

4. The system according to claim 3, wherein, The vehicle platform also includes a vehicle alignment device disposed on the turntable, wherein the vehicle alignment device is configured to align the vehicle to a known position on the vehicle platform.

5. The system according to any one of claims 1 or 2, wherein, The vehicle is equipped with multiple sensors, and the system includes multiple calibration targets arranged in a defined space at known fixed target positions, wherein when the vehicle is oriented at the known reference vehicle position, the multiple calibration targets are aligned with the multiple sensors of the vehicle for calibrating the multiple sensors of the vehicle.

6. The system according to claim 5, wherein, The vehicle platform is configured to individually orient multiple vehicles, each having different vehicle categories and each including multiple sensors, to different vehicle category reference locations associated with each vehicle category, wherein, when a selected vehicle of each vehicle category is oriented to a vehicle category reference location associated with the selected vehicle, a set of multiple targets is aligned with the multiple sensors on the selected vehicle for calibration of the multiple sensors on the selected vehicle.

7. The system according to claim 6, wherein, The multiple targets include multiple sets of targets, and each set of targets is associated with a separate vehicle category.

8. The system according to claim 7, wherein, The vehicle platform includes a turntable rotatable about a vertical axis to rotate vehicles disposed on the vehicle platform, wherein the turntable is configured to rotate to orient each vehicle to an associated vehicle category reference position.

9. The system according to claim 8, wherein, The vehicle platform also includes a vehicle alignment device disposed on the turntable, wherein the vehicle alignment device is configured to align the vehicle to a known position on the vehicle platform.

10. A vehicle testing and calibration system for calibrating sensors on equipped vehicles, the system comprising: A vehicle platform for receiving individual vehicles equipped with at least one sensor, wherein the vehicles have a vehicle category that defines the position of the at least one sensor on the vehicle, wherein the vehicle platform includes a vehicle centering device and a turntable, and the vehicle platform is configured to orient the vehicle to a reference position. Multiple targets, each of which is arranged at a known fixed target position within a defined space around the vehicle platform, wherein the vehicle platform is configured to individually orient multiple vehicles of different vehicle categories, each including at least one sensor, to a different reference position associated with each vehicle category, and wherein, when a selected vehicle of each vehicle category is oriented to the reference position associated with the vehicle, at least one of the targets is aligned with at least one sensor on the selected vehicle for calibrating the at least one sensor on the selected vehicle; Wherein, the known target location is based on the vehicle category, and when the vehicle is oriented at the reference location, at least one of the targets is aligned with at least one sensor of the vehicle for calibration of the at least one sensor of the vehicle.

11. The system according to claim 10, wherein, The system is configured to orient a vehicle having multiple sensors and belonging to at least one vehicle category to a reference position for the vehicle category, wherein, when the vehicle having multiple sensors is at the reference position, multiple targets are aligned with the multiple sensors for calibration of the multiple sensors.

12. The system according to any one of claims 10 or 11, wherein, The multiple targets include multiple sets of targets, and each set of targets is associated with a separate vehicle category.

13. The system according to any one of claims 10 or 11, wherein, The centering device includes a front centering device for receiving the front wheel assembly of the vehicle and a rear centering device for receiving the rear wheel assembly of the vehicle.

14. The system according to any one of claims 10 or 11, wherein, The turntable is configured to rotate the vehicle when the vehicle is positioned on the centering device.

15. The system according to any one of claims 10 or 11, wherein, The defined space includes a vehicle bay, into which the vehicle can be driven to reach the centering device.

16. The system according to any one of claims 10 or 11, wherein, The vehicle platform includes a dynamic vehicle platform on which the tires and wheel assemblies of the vehicle can be operated to simulate vehicle driving.

17. A method for testing and calibrating sensors on an equipment vehicle, the method comprising: Multiple targets are provided for calibrating sensors on equipped vehicles of multiple vehicle categories, wherein each vehicle category defines the location of at least one sensor on the vehicle of that vehicle category. Orient the vehicle at a reference position on the vehicle platform; The vehicle is moved based on the vehicle category of the oriented vehicle to align the plurality of targets with the sensor for calibration.

18. The method according to claim 17, wherein, The vehicle platform includes a centering device for orienting the vehicle to the reference position.

19. The method according to any one of claims 17 or 18, wherein, Moving the vehicle includes rotating the vehicle on the vehicle platform.

20. The method according to claim 19, wherein, The vehicle platform includes a turntable, and the centering device is mounted on the turntable.

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