Vehicle headlamp light distribution performance detection device and detection method
By combining technologies such as illuminance sensor arrays, vision sensors, and lidar, dynamic detection of vehicle headlight light distribution performance is achieved, solving the problems of low detection efficiency and high cost in existing technologies, and realizing efficient and accurate headlight detection.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- JILIN UNIVERSITY
- Filing Date
- 2026-05-11
- Publication Date
- 2026-06-05
AI Technical Summary
Existing vehicle headlight light distribution performance testing technologies cannot achieve accurate testing under dynamic conditions. They rely on static large light curtains and fixed darkrooms, resulting in low testing efficiency, high costs, and difficulty in rapid deployment and integration into the production process.
By employing an illuminance acquisition device, a positioning device, and a detection platform, combined with an illuminance sensor array, a vision sensor, a lidar, and GPS, and using the Kalman filter algorithm and the Kriging interpolation method, dynamic reconstruction and accurate detection of vehicle light pattern distribution are achieved.
It can guarantee detection accuracy under both static and dynamic conditions, improve detection efficiency and flexibility, reduce human error, and realize fully automated detection.
Smart Images
Figure CN122149816A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of motor vehicle testing technology, and particularly relates to a device and method for testing the light distribution performance of vehicle headlights. Background Technology
[0002] GB4599-2024, "Automotive Road Lighting Devices and Systems," sets forth requirements for road lighting devices and systems, including low beam headlights, high beam headlights, front fog lights, and cornering lights, used on Category M and N vehicles. Vehicle lights are crucial components for ensuring driving safety; their light intensity and light distribution directly affect the visibility of drivers and other road users, thus being closely related to nighttime traffic safety. Testing devices, as a means of assessing the light distribution performance of vehicle lights, indirectly contribute to ensuring road safety.
[0003] The testing method for the light distribution performance of vehicle headlights has a great impact on the test results. Based on different testing principles, many different testing techniques and methods have been developed. Based on the development and current status of vehicle headlight light distribution performance testing techniques and methods at home and abroad, the main ones are: (1) manual point-by-point testing method; (2) light distribution screen point-by-point testing method; (3) screen coordinate positioning testing method; (4) lamp rotation method.
[0004] The aforementioned vehicle headlight testing methods cannot test the light distribution performance of vehicles in motion. Furthermore, most require manual adjustment of the vehicle's position, making it difficult to ensure a constant distance and orientation between the device and the headlights during testing. These methods also operate under static, large-light-curtain testing conditions and heavily rely on dedicated, fixed darkroom environments. The high construction and maintenance costs of fixed darkrooms hinder rapid deployment of testing equipment in the field, failing to meet the demands of modern industrial manufacturing for efficient testing. Therefore, existing solutions suffer from over-reliance on static, large-light-curtain testing, inability to perform dynamic, moving-vehicle testing, and difficulty in balancing testing accuracy and efficiency. They also exhibit inherent problems such as strong dependence on fixed facilities, poor deployment flexibility, and difficulty in integrating into dynamic production processes. Summary of the Invention
[0005] In view of this, the present invention aims to provide a vehicle headlight light distribution performance testing device and testing method, which eliminates the reliance on a fixed dark chamber and a large light curtain, and can ensure that the position of the test vehicle meets the requirements under both static and dynamic testing conditions. Combined with an illuminance sensor array and a first illuminance sensor, it greatly improves the flexibility and efficiency of the testing.
[0006] To achieve the above objectives, the technical solution created by this invention is implemented as follows: A vehicle headlight light distribution performance testing device, comprising: Illuminance acquisition device, used to collect illuminance values of vehicle headlights; A positioning device is used to collect the relative pose information between the illuminance acquisition device and the vehicle lights; The detection platform is used to carry the illuminance acquisition device and the positioning device, and to move the illuminance acquisition device and the positioning device. The main control unit is connected to the illuminance acquisition device, positioning device, and detection platform. The illuminance acquisition device includes an illuminance detection and processing device, a sensor motion mechanism, and a first data processor. The sensor motion mechanism is communicatively connected to the first data processor, and its output is connected to the illuminance detection and processing device. The sensor motion mechanism receives commands from the main control mechanism and moves the illuminance detection and processing device to a preset height. The illuminance detection and processing device transmits the illuminance values of the vehicle headlights to the first data processor. The positioning device converts the coordinates in the relative pose information of all spatial positions to a detection coordinate system with the vehicle headlights as the origin, and transmits all coordinates to the first data processor through the main control mechanism. The first data processor reconstructs a two-dimensional light pattern distribution grayscale image based on all coordinates and their corresponding illuminance values, and transmits the two-dimensional light pattern distribution grayscale image to the main control mechanism. The main control unit compares all coordinates and illuminance values in the received two-dimensional light pattern distribution grayscale image with its internally stored vehicle lighting regulations and standards library.
[0007] Furthermore, the sensor motion mechanism includes a mounting frame, a lead screw, a first drive motor, a lead screw seat, and guide rods. The lead screw is rotatably mounted inside the mounting frame, and its bottom end is connected to the first drive motor, which is also mounted inside the mounting frame. The mounting frame is rotatably mounted on the detection platform, and the top end of the lead screw is rotatably connected to the mounting frame. The illuminance detection and processing device is mounted on the lead screw seat, which is threadedly connected to the lead screw. Guide rods are provided on both sides of the lead screw, passing through the lead screw seat and being mounted inside the mounting frame. The lead screw seat reciprocates along the length of the guide rods.
[0008] Furthermore, the mounting bracket includes a mounting plate and two fixing plates, which are respectively fixed to the top and bottom of one side of the mounting plate. The top of the lead screw is rotatably connected to the fixing plate located at the top. The first drive motor is mounted on the fixing plate located at the bottom. The top and bottom of the two guide rods are respectively connected to the two fixing plates.
[0009] Furthermore, the illuminance detection and processing device includes a substrate, a first illuminance sensor, and a second illuminance sensor. The first illuminance sensor is disposed in the center of the front side of the substrate, and multiple second illuminance sensors are disposed on the outer side of the first illuminance sensor. The multiple second illuminance sensors are evenly arranged around the first illuminance sensor to form an illuminance sensor array. The first illuminance sensor and the second illuminance sensor transmit the illuminance values of the vehicle lights they collect to the main control mechanism.
[0010] Furthermore, the positioning device includes a visual sensor, a lidar, a GPS, and a second data processor. The visual sensor, lidar, and GPS are all mounted on the detection platform. The visual sensor is located in front of the first illuminance sensor, and the GPS is located between the visual sensor and the first illuminance sensor. There are two lidars, which are symmetrically arranged on both sides of the visual sensor. The visual sensor, the two lidars, and the GPS collect relative pose information and transmit it to the second data processor. The second data processor calculates the relative distance and angle based on the received relative pose information.
[0011] Furthermore, the inspection platform includes an inspection vehicle, wheels, a second drive motor, a rotating platform, and a third drive motor. There are four wheels, which are symmetrically arranged on the sides of the inspection vehicle. The second drive motor drives the wheels to rotate. Visual sensors, lidar, and GPS are all installed on the inspection vehicle. A rotating platform is located in the middle of the top surface of the inspection vehicle. A fixed plate at the bottom is installed on the top surface of the rotating platform. The rotating platform is connected to the output end of the third drive motor.
[0012] Furthermore, the main control mechanism includes a main controller, which is located inside the testing vehicle. The main controller is communicatively connected to a first illuminance sensor, a second illuminance sensor, a first drive motor, a first data processor, a second data processor, a second drive motor, and a third drive motor.
[0013] A method for testing the light distribution performance of vehicle lamps includes the following steps: S1: Start the visual sensor, LiDAR and GPS, and the visual sensor, LiDAR and GPS continuously collect relative pose information; S2: The main controller receives the relative pose information collected in step S1, analyzes the residual of the relative pose information in real time, adjusts the trust weights of the relative pose information collected by the vision sensor, lidar and GPS through the Kalman filter algorithm, and dynamically outputs the relative distance and angle between the detection vehicle and the headlights of the vehicle to be detected. S3: When the relative distance between the test vehicle and the headlight to be tested meets the position specified in the headlight regulations standard library, and the illuminance sensor array is adjusted according to the relative angle with the headlight to be tested, the test personnel manually turn on the headlight to be tested. S4: The main controller sends an execution detection command to the illuminance acquisition device. The first illuminance sensor and the second illuminance sensor start working after receiving the execution detection command. S5: The main controller has pre-stored vehicle lamp type information and vehicle lamp regulation standard library. The main controller retrieves the corresponding core test area coordinates from the vehicle lamp type information and vehicle lamp regulation standard library according to the input vehicle lamp type. The core test area coordinates are mapped to the relative distance and angle between the test vehicle and the vehicle lamp to be tested in step S2 into the relative motion coordinate system of the test vehicle, and the scanning boundary is obtained. The preset sampling density is generated according to the effective detection area of the sensor unit and the total area within the scanning boundary to ensure full coverage of the part within the scanning boundary. Illuminance and relative pose information are collected within the scanning boundary according to the preset sampling density. S6: The first data processor filters and eliminates noise from the collected illuminance values. The second data processor transforms the coordinates of all spatial positions in the relative pose information to the detection coordinate system with the headlight as the origin, and transmits all coordinates to the first data processor through the main controller. The first data processor reconstructs the preprocessed illuminance values and relative pose information into a continuous two-dimensional light pattern distribution grayscale image using the Kriging interpolation method. The inspection vehicle moves along a preset inspection path, and the illuminance sensor array scans and samples. The first data processor generates a low-resolution global distribution map based on the illuminance value and the coordinates of the inspection vehicle's position points in the relative pose information. The main controller analyzes the low-resolution global distribution map, uses the square of the measurement uncertainty of the second illuminance sensor within its nominal range as a threshold, compares the estimated variance of each pixel with this threshold, and identifies the regions where the variance exceeds the threshold. The main controller controls the illuminance acquisition device to perform sampling supplementation or increase the sampling density of the first illuminance sensor in the corresponding region. The first data processor corrects the illuminance value collected by the first illuminance sensor. When the estimated variance decreases below the threshold, the first data processor reconstructs a continuous two-dimensional light pattern distribution grayscale image based on the corrected illuminance value and the coordinates of the spatial coordinate points. The two-dimensional light pattern distribution grayscale image is then packaged into a complete light pattern data package. S7: The first data processor uploads the optical data packet to the main controller. The main controller uses the edge detection algorithm in image processing technology to identify the two-dimensional optical distribution grayscale image of the optical data packet, extract the light and dark cutoff lines and form the contour curve to determine the position of the optical boundary. Based on the determined light pattern boundary position, the measured illuminance information corresponding to the light pattern boundary position of the spatial position point specified in the vehicle lighting regulations and standards library on the two-dimensional light pattern distribution grayscale map is extracted, and it is compared point by point with the illuminance value (or allowable range) corresponding to the spatial position point in the vehicle lighting regulations and standards library, the deviation is calculated and quantified. S8: The main controller generates a test report based on the comparative analysis and quantification results in step S7. The test report includes the overall conclusion that it complies with the regulations of the vehicle lighting standards library, the illuminance value deviation data of spatial location points, and a visual light pattern comparison chart.
[0014] Furthermore, the relative pose information includes the absolute position and velocity information of the illumination detection processing device and the headlight under test calculated by GPS using the Kalman filter algorithm; the lidar emits a laser beam to the headlight under test and receives the echo, directly measuring the distance to the headlight surface; the vision sensor captures an image containing markers around the headlight under test, and calculates the pose data through image feature point matching and parallax.
[0015] Furthermore, when the relative distance and angle between the main controller's dynamic output test vehicle and the headlight under test do not meet the requirements specified in the headlight regulations standard library, a movement command is generated based on the distance deviation obtained by comparing the relative distance and angle of the headlight under test with the requirements of the headlight regulations standard library. The second drive motor drives the wheels to rotate according to the received movement command, controls the test vehicle to adjust its position, the first drive motor drives the lead screw to rotate, and the third drive motor drives the rotating platform to rotate, thereby realizing the position and orientation adjustment of the illuminance sensor array until the relative distance and angle between the dynamic output illuminance sensor array and the headlight under test meet the requirements specified in the headlight regulations standard library.
[0016] Compared with the prior art, the present invention can achieve the following beneficial effects: (1) The detection vehicle described in this invention, together with the vision sensor, lidar and GPS, can ensure that the position of the detection vehicle meets the requirements in both static and dynamic detection situations. The combination of the illuminance sensor array and the first illuminance sensor greatly improves the flexibility and efficiency of detection.
[0017] (2) The vehicle lamp light distribution performance testing method of the present invention improves the reliability of the test by initially reconstructing a continuous two-dimensional light pattern distribution grayscale image, then performing targeted supplementary sampling on the light pattern illuminance distribution characteristics, and reconstructing a continuous two-dimensional light pattern distribution grayscale image again.
[0018] (3) The illuminance sensor array described in this invention consists of a high-precision illuminance sensor and multiple general-precision illuminance sensors. During the initial detection, the high-precision illuminance sensor and the general-precision illuminance sensor work simultaneously to obtain preliminary light pattern data packets. Then, based on whether the preliminary data meets the standard, the high-precision illuminance sensor is controlled to supplement the collection of data in the corresponding area, thus taking into account both detection accuracy and detection efficiency.
[0019] (4) The vehicle lamp light distribution performance testing method described in this invention can automatically generate testing paths, automatically process data, and automatically generate detailed testing reports, realizing fully automated testing from dynamic tracking to data output, greatly reducing human operation errors and improving the repeatability and consistency of testing. Attached Figure Description
[0020] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 A schematic diagram of the structure of the vehicle headlight light distribution performance testing device described in an embodiment of the present invention; Figure 2 for Figure 1 The main view; Figure 3 A control principle block diagram of a vehicle headlight light distribution performance testing device according to an embodiment of the present invention; Figure 4 for Figure 1 Front view of the medium illuminance sensor array and the first illuminance sensor; Figure 5 The flowchart illustrates the method for testing the light distribution performance of vehicle lights as described in the embodiments of the present invention.
[0021] Explanation of reference numerals in the attached figures: 1. Illuminance acquisition device; 2. Positioning device; 3. Detection platform; 4. Main control mechanism; 5. Human-computer interaction mechanism; 10. Illuminance detection and processing device; 11. Sensor motion mechanism; 12. First data processor; 101. Substrate; 102. First illuminance sensor; 103. Second illuminance sensor; 111. Mounting bracket; 112. Lead screw; 113. First drive motor; 114. Lead screw seat; 115. Guide rod; 1111. Mounting plate; 1112. Fixing plate; 20. Vision sensor; 21. LiDAR; 22. GPS; 23. Secondary data processor; 30. Inspection vehicle; 31. Wheels; 32. Rotating platform; 40. Main controller. Detailed Implementation
[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not constitute a limitation thereof.
[0023] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.
[0024] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.
[0025] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0026] The invention will now be described in detail with reference to the accompanying drawings and embodiments.
[0027] like Figures 1 to 4 As shown, a vehicle headlight light distribution performance testing device includes: Illuminance acquisition device 1 is used to collect the illuminance value of vehicle headlights; Positioning device 2 is used to collect the relative pose information between illumination acquisition device 1 and vehicle lights; The detection platform 3 is used to carry the illuminance acquisition device 1 and the positioning device 2, and to move the illuminance acquisition device 1 and the positioning device 2. Main control unit 4 is communicatively connected to illuminance acquisition device 1, positioning device 2 and detection platform 3; The illuminance acquisition device 1 includes an illuminance detection and processing device 10, a sensor motion mechanism 11, and a first data processor 12. The sensor motion mechanism 11 is communicatively connected to the first data processor 12, and the output of the sensor motion mechanism 11 is connected to the illuminance detection and processing device 10. The sensor motion mechanism 11 receives commands from the main control mechanism 4 and moves the illuminance detection and processing device 10 to a preset height. The illuminance detection and processing device 10 transmits the illuminance values of the vehicle headlights to the first data processor 12. The positioning device 2 converts the coordinates in the relative pose information of all spatial position points to the detection coordinate system with the vehicle headlights as the origin, and transmits all coordinates to the first data processor 12 through the main control mechanism 4. The first data processor 12 reconstructs a two-dimensional light pattern distribution grayscale image based on all coordinates and their corresponding illuminance values, and transmits the two-dimensional light pattern distribution grayscale image to the main control mechanism 4. The main control unit 4 compares all coordinates and illuminance values in the received two-dimensional light pattern distribution grayscale image with its internally stored vehicle lighting regulations and standards library, and determines whether the light distribution performance of the tested vehicle lamp meets the requirements of the vehicle lighting regulations and standards library. The specific requirements of the vehicle lighting regulations and standards library are relevant national standards such as GB 4599-2024 "Automotive Road Lighting Devices and Systems" and GB 5920-2024 "Automotive and Trailer Light Signal Devices and Systems".
[0028] The preset height is the headlight illumination collection height specified in the vehicle headlight regulations and standards library.
[0029] The sensor motion mechanism 11 includes a mounting frame 111, a lead screw 112, a first drive motor 113, a lead screw seat 114, and a guide rod 115. The lead screw 112 is rotatably mounted inside the mounting frame 111, and the bottom end of the lead screw 112 is connected to the first drive motor 113, which is also mounted inside the mounting frame 111. The mounting frame 111 is rotatably mounted on the detection platform 3, and the top end of the lead screw 112 is rotatably connected to the mounting frame 111. The illuminance detection and processing device 10 is mounted on the lead screw seat 114, which is threadedly connected to the lead screw 112. Guide rods 115 are respectively provided on both sides of the lead screw 112. The guide rods 115 pass through the lead screw seat 114 and are located inside the mounting frame 111. The lead screw seat 114 reciprocates along the length of the guide rods 115.
[0030] The first drive motor 113 operates, driving the lead screw 112 to rotate, which in turn drives the illuminance detection and processing device 10 to move up and down along the guide rod 115 through the lead screw seat 114, so as to adjust the illuminance detection and processing device 10 to the preset detection position to collect the illuminance value of the vehicle headlights.
[0031] The mounting bracket 111 includes a mounting plate 1111 and two fixing plates 1112. The two fixing plates 1112 are respectively fixed to the top and bottom of one side of the mounting plate 1111. The top of the lead screw 112 is rotatably connected to the fixing plate 1112 located at the top. The first drive motor 113 is mounted on the fixing plate 1112 located at the bottom. The top and bottom of the two guide rods 115 are respectively connected to the two fixing plates 1112.
[0032] The lead screw 112 drives the illuminance detection and processing device 10 to move up and down between the two fixed plates 1112 along the guide rod 115, thereby limiting the vertical movement range of the illuminance detection and processing device 10. The first drive motor 113 is fixed to the fixed plate 1112 located at the bottom. The lead screw 112 is set perpendicular to the two fixed plates 1112, and the movement direction of the lead screw seat 114 is guided by the two guide rods 115 to ensure the stability of the movement of the illuminance detection and processing device 10.
[0033] The illuminance detection and processing device 10 includes a substrate 101, a first illuminance sensor 102, and a second illuminance sensor 103. The first illuminance sensor 102 is disposed in the center of the front side of the substrate 101, and twenty-four second illuminance sensors 103 are disposed on the outer side of the first illuminance sensor 102. The twenty-four second illuminance sensors 103 are evenly arranged around the first illuminance sensor 102 to form an illuminance sensor array. The first illuminance sensor 102 and the second illuminance sensor 103 transmit the collected vehicle headlight illuminance values to the main control mechanism 4.
[0034] When the illuminance detection and processing device 10 is working, the main control mechanism 4 outputs a detection path according to the internally preset vehicle lighting regulations standard library. The positioning device 2 collects all spatial position points on the detection path and moves to the spatial position points via the detection platform 3. The illuminance sensor array formed by twenty-four second illuminance sensors 103 performs a coarse scan. At the same time, the first illuminance sensor 102 also performs a scan. The detection platform 3 moves according to the detection path. The first data processor 12 obtains the vehicle lighting illuminance value based on the illuminance sensor array and the relative pose information obtained by the positioning device 2, and generates a low-resolution global distribution map through Kriging interpolation. The main control mechanism 4 uses the image... The edge detection algorithm in the processing technology identifies key areas in the low-resolution global distribution map, such as the inflection points of the light and dark cutoff lines and gradient change areas, which correspond to the vehicle lighting regulations and standards library. It then outputs a movement command to the detection platform 3, which moves the first illuminance sensor 102 to the key area. The first illuminance sensor 102 performs high-precision measurement, and the illuminance value collected by the second illuminance sensor 103 is corrected based on the illuminance value collected by the first illuminance sensor 102. The corrected data is then used to reconstruct a two-dimensional light distribution grayscale map using Kriging interpolation, achieving an intelligent balance between accuracy and efficiency.
[0035] The first illuminance sensor is a high-precision illuminance sensor, and the second illuminance sensor is a general-precision illuminance sensor. According to the current national metrological verification procedure "JJG 245-2005 Verification Procedure for Illuminance Meters" in the standard for Class I illuminance meters, the measurement uncertainty of the high-precision illuminance sensor is no greater than ±3%, and the measurement uncertainty of the general-precision illuminance sensor is no greater than ±5%, and it has a faster response speed.
[0036] The positioning device 2 includes a visual sensor 20, a lidar 21, a GPS 22, and a second data processor 23. The visual sensor 20, lidar 21, and GPS 22 are all mounted on the detection platform 3. The visual sensor 20 is located in front of the first illuminance sensor 102, and the GPS 22 is located between the visual sensor 20 and the first illuminance sensor 102. There are two lidars 21, which are symmetrically arranged on both sides of the visual sensor 20. The visual sensor 20, the two lidars 21, and the GPS 22 collect relative pose information and transmit it to the second data processor 23. The positioning device 2 uses the second data processor 23 to transform the coordinates to the detection coordinate system. The second data processor 23 has a positioning perception data processing unit. The positioning perception data processing unit calculates the relative distance and angle based on the received relative pose information and uses a Kalman filter algorithm to provide a key spatial reference for maintaining a constant detection distance. At the same time, the detected relative pose information is transmitted to the first data processor 12 via the main control mechanism 4.
[0037] The vision sensor 20 can be a binocular vision sensor.
[0038] The detection platform 3 includes a detection vehicle 30, wheels 31, a second drive motor, a rotating platform 32, and a third drive motor. There are four wheels 31, which are symmetrically arranged on the side of the detection vehicle 30. The second drive motor drives the wheels 31 to rotate. The vision sensor 20, the lidar 21, and the GPS 22 are all installed on the detection vehicle 30. The rotating platform 32 is located in the middle of the top surface of the detection vehicle 30. The fixed plate 1112 at the bottom is installed on the top surface of the rotating platform 32. The rotating platform 32 is connected to the output end of the third drive motor. Both the third drive motor and the second drive motor are installed inside the detection vehicle 30.
[0039] The main control mechanism 4 receives the relative pose information and compares it with the relative pose information specified in the vehicle lighting regulations standard library. When the relative pose information is inconsistent, the main control mechanism 4 outputs control information to the second drive motor and the third drive motor. The control information includes relative distance and angle. The position of the detection vehicle 30 is adjusted according to the relative distance, and the height and angle of the illuminance sensor array are adjusted according to the angle. At this time, the first drive motor 113 and the third drive motor drive the rotating platform 32 to work, and the second drive motor drives the rotating platform 32 and the four wheels 31 to work, ensuring that the illuminance sensor array can quickly adjust to the corresponding coordinate position on the detection path for detection.
[0040] The substrate 101 can reciprocate in the vertical direction under the drive of the lead screw 112. The substrate 101 can rotate along the axis of the rotating platform 32 under the drive of the rotating platform 32. Through the above-mentioned spatial movement of the substrate 101, different light-receiving positions can be covered.
[0041] The main control mechanism 4 includes a main controller 40, which is located inside the detection vehicle 30. The main controller 40 is communicatively connected to the first illuminance sensor 102, the second illuminance sensor 103, the first drive motor 113, the first data processor 12, the second data processor 23, the second drive motor, and the third drive motor.
[0042] The main controller 40 is also connected to the human-machine interface mechanism 5 to provide an operating interface for users. The human-machine interface mechanism 5 includes an operation panel and a remote control. Control commands are output through the operation panel and the remote control, and detection results and reports can be output by the human-machine interface mechanism 5.
[0043] The main controller 40 has pre-stored information on vehicle lamp types and a library of vehicle lamp regulations and standards.
[0044] In actual operation, the testing vehicle 30 moves along the testing path, and the illuminance sensor array and the first illuminance sensor 102 scan and collect illuminance values. At the same time, the vision sensor 20, the lidar 21, and the GPS 22 acquire the relative pose information of the device in real time. The first data processor 12 reconstructs a two-dimensional light pattern distribution grayscale image based on the acquired illuminance values and relative pose information, and transmits it to the main controller 40. The main controller 40 compares all the coordinates and illuminance values in the received two-dimensional light pattern distribution grayscale image with its internally stored vehicle lamp regulatory standard library, and determines whether the light distribution performance of the tested vehicle lamp meets the requirements of the vehicle lamp regulatory standard library.
[0045] An array of illuminance sensors consisting of twenty-four second illuminance sensors 103 and a first illuminance sensor 102 are driven by a lead screw 112 to move up and down along a guide rod 115, and their angles are adjusted by the rotation of a rotating platform 32 to cover different light-receiving positions.
[0046] When this application is in operation, it is first powered on. The main control mechanism 4, positioning device 2, illuminance acquisition device 1 and human-machine interaction mechanism 5 perform hardware self-test and parameter initialization as preparation for testing. After the self-test and parameter initialization are completed, the human-machine interaction mechanism 5 outputs the start test command and marks are pre-attached around the headlight to be tested.
[0047] like Figure 5 As shown, a method for testing the light distribution performance of vehicle lamps includes the following steps: S1: Start the vision sensor 20, lidar 21 and GPS 22, and the vision sensor 20, lidar 21 and GPS 22 continuously collect relative pose information; The relative pose information includes: GPS 22 calculates the absolute position and speed information of the illumination detection processing device 10 and the vehicle headlight to be detected. GPS 22 can be a u-blox ZED-F9P GPS manufactured by U-blox GmbH, Switzerland; LiDAR 21 emits a laser beam to the vehicle headlight to be detected and receives the echo, directly measuring the distance to the surface of the headlight; vision sensor 20 captures an image containing markers around the vehicle headlight to be detected, calculates pose data through image feature point matching and disparity calculation, and transmits the above relative pose information to the second data processor 23. The second data processor 23 calculates the relative distance and angle based on the relative pose information and through the Kalman filter algorithm, and transmits it to the main controller 40. The absolute position is the longitude and latitude coordinates of the detection platform 3 calculated by GPS22; the vision sensor 20 synchronously acquires left and right images including the vehicle lights and surrounding preset markers, and processes the left and right images using a scale-invariant feature transformation algorithm to obtain a set of matching feature point pairs with corresponding relationships. For each pair of matching points, the difference in their pixel abscissa is calculated, i.e., the disparity; based on the disparity and the calibration parameters of the vision sensor 20, the three-dimensional coordinates of each matching point are calculated through triangulation, thereby solving the pose data; S2: The main controller 40 receives the relative pose information collected in step S1, analyzes the residual of the relative pose information in real time, adjusts the trust weight of the relative pose information collected by the vision sensor 20, the lidar 21 and the GPS 22 through the Kalman filter algorithm, and dynamically outputs the relative distance and angle between the detection vehicle 30 and the headlights to be detected. When the relative distance and angle between the main controller 40 and the test vehicle 30 do not meet the requirements specified in the vehicle lighting regulations standard library, the main controller 40 generates a movement command based on the distance deviation obtained by comparing the relative distance and angle between the test vehicle 30 and the requirements specified in the vehicle lighting regulations standard library. The second drive motor drives the wheel 31 to rotate according to the received movement command, controls the test vehicle 30 to adjust its position, the first drive motor 113 drives the lead screw 112 to rotate, and the third drive motor drives the rotating platform 32 to rotate, thereby realizing the pose adjustment of the illuminance sensor array until the relative distance and angle between the dynamic output illuminance sensor array and the test vehicle 30 meet the requirements specified in the vehicle lighting regulations standard library. The acquisition of the relative pose information and the movement of the detection vehicle 30 are continuously cycled throughout the entire detection period, forming a closed-loop control to ensure that the detection vehicle 30 and the moving vehicle lamp under test always maintain the distance and angle specified in the vehicle lamp regulation standard library. S3: When the relative distance between the test vehicle 30 and the headlight to be tested meets the position specified in the headlight regulations standard library, and the illuminance sensor array is adjusted according to the relative angle with the headlight to be tested, the test personnel manually turn on the headlight to be tested. S4: The main controller 40 sends an execution detection command to the illuminance acquisition device 1. The first illuminance sensor 102 and the second illuminance sensor 103 start working after receiving the execution detection command. S5: The main controller 40 has pre-stored vehicle lamp type information and vehicle lamp regulation standard library. The main controller 40 retrieves the corresponding core test area coordinates from the vehicle lamp type information and vehicle lamp regulation standard library according to the input vehicle lamp type. The core test area coordinates are mapped to the relative distance and angle between the detection vehicle 30 and the vehicle lamp to be tested in step S2 into the relative motion coordinate system of the detection vehicle 30, and the scanning boundary is obtained. The preset sampling density is generated according to the effective detection area of the sensor unit and the total area within the scanning boundary to ensure full coverage of the part within the scanning boundary. Illuminance and relative pose information are collected within the scanning boundary according to the preset sampling density. The area to be measured is rasterized into a grid of M rows and N columns, and the total number of spatial location points (M) required to completely cover the area is determined. (N), and generate a series of ordered coordinate points in the order of column scanning to form a two-dimensional grid-like predetermined detection path that dynamically covers the core test area, i.e., the scanning boundary; The main controller 40 outputs working commands to the first drive motor 113, the second drive motor, and the third drive motor, driving the first illuminance sensor 102 and the second illuminance sensor 103 to scan along the generated two-dimensional grid-shaped predetermined detection path, collecting the illuminance values of all spatial position points on the two-dimensional grid-shaped predetermined detection path, and collecting the relative pose information of the corresponding spatial position points through the vision sensor 20, the lidar 21, and the GPS 22. S6: The second data processor 23 transforms the coordinates of all spatial position points in the relative pose information to the detection coordinate system with the vehicle headlight as the origin, and transmits all coordinates to the first data processor 12 through the main controller 40; the first data processor 12 reconstructs the preprocessed illuminance value and relative pose information into a continuous two-dimensional light pattern distribution grayscale image through Kriging interpolation. The process of reconstructing a continuous two-dimensional light pattern distribution grayscale image is as follows: Using Kriging interpolation, dynamically acquired discrete spatial location points distributed in three-dimensional space are accurately reconstructed into a continuous two-dimensional light pattern distribution grayscale image on a virtual detection plane S at a fixed distance specified in the vehicle lighting regulations standard library. The specific steps are as follows: First, Kriging interpolation calculates the illuminance value of the vehicle light based on the coordinates of all spatial location points and the illuminance value of the vehicle light. Then, a mathematical model that quantifies the attenuation of the similarity of illuminance values as the distance between two points increases is fitted using a nonlinear least squares method. Specifically, the distance h between all adjacent spatial location points and the difference in their illuminance values are calculated. The square of h yields a series of (h, The data points are fitted using a nonlinear least squares method to obtain a continuous mathematical model. This model quantitatively describes the statistical relationship between the illuminance difference and the distance between any two points in space within the current detection environment. Subsequently, for each pixel with an unknown illuminance value on the virtual plane S... Based on a mathematical model, a system of Kriging equations is solved. This system of Kriging equations is solved using the mathematical criterion of ensuring that the estimated values are unbiased and that the variance of the estimated values is minimized, thereby obtaining the pixel points whose illuminance values are unknown. Optimal weight combination of illuminance ; Unknown pixel with unknown illuminance value The variance of the estimated value It is obtained directly through the process of solving the Kriging equations; Unknown pixel with unknown illuminance value Optimal illuminance estimate By sampling all relevant surrounding points The illuminance values are obtained by weighted summation, and the specific calculation formula is as follows:
[0048] In the formula For the j-th pixel Q with an unknown illuminance value on the virtual detection plane S... j The estimated illuminance value; Let Q be the weighting coefficient, representing the i-th relevant sampling point. i The observed value Lv (Qi) For estimating the j-th target point The weighting of the illuminance value is a dimensionless scalar; Lv(Qi) Given the observed quantities, in three-dimensional space, the i-th related sampling point Q i The actual measured illuminance value at the location; Optimal unbiased estimate of illuminance and the variance of its estimated value These correspond to the illuminance value and the accuracy of the illuminance value for each unknown pixel on the virtual detection plane.
[0049] The inspection vehicle 30 moves along a preset inspection path, and the illuminance sensor array scans and samples. The first data processor 12 generates a low-resolution global distribution map using Kriging interpolation based on the illuminance value and the coordinates of the workpiece position points in the relative pose information. The main controller 40 analyzes the low-resolution global distribution map, uses the square of the measurement uncertainty of the second illuminance sensor 103 within its nominal range as a threshold, compares the estimated variance of each pixel with this threshold, and identifies the regions where the variance exceeds the threshold. The main controller 40 controls the illuminance acquisition device 1 to perform sampling supplementation or increase the sampling density of the first illuminance sensor 102 in the corresponding region. The first data processor 12 corrects the illuminance value collected by the first illuminance sensor 102. When the estimated variance decreases below the threshold, a continuous two-dimensional light pattern distribution grayscale map is reconstructed based on the corrected illuminance value and the coordinates of the spatial coordinate points. The two-dimensional light pattern distribution grayscale map is then packaged into a complete light pattern data package. S7: The first data processor 12 uploads the light pattern data packet to the main controller 40. The main controller 40 uses the edge detection algorithm in image processing technology to identify the two-dimensional light pattern distribution grayscale image of the light pattern data packet, extract the light and dark cutoff line and form the contour curve to determine the light pattern boundary position, and provide a basis for the positioning and deviation quantification of the test points specified in the subsequent vehicle lighting regulations and standards library. Based on the determined light pattern boundary position, the measured illuminance information corresponding to the light pattern boundary position of the spatial position point specified in the vehicle lighting regulations and standards library on the two-dimensional light pattern distribution grayscale map is extracted, and it is compared point by point with the illuminance value (or allowable range) corresponding to the spatial position point in the vehicle lighting regulations and standards library, the deviation is calculated and quantified. Calculate the deviation (or excess amount) between the measured illuminance value at each spatial location point and the value specified in the vehicle lighting regulations standard library. Select the number of spatial location points exceeding the limit, the proportion of exceeding the limit, and the maximum deviation value as quantitative evaluation indicators. Among them, the number of exceeding the limit is the total number of spatial location points exceeding the standard illuminance allowable range, and the proportion of exceeding the limit is the ratio of the number of exceeding points to the total number of test points. Based on the above indicators, determine whether the light distribution performance of the tested vehicle lamp meets the requirements of the vehicle lighting regulations standard library. Combined with the deviation distribution at each location point, generate a visual comparison chart of "measured light pattern - standard light pattern" (clearly marking the excess area and the degree of deviation). S8: The main controller 40 generates a test report based on the comparative analysis and quantification results in step S7. The test report includes the overall conclusion that it complies with the regulations of the vehicle lighting standards library, the illuminance value deviation data of the spatial location points, and the visual light pattern comparison chart.
[0050] This application eliminates the reliance on a fixed darkroom and a large light curtain, ensuring a constant position under both static and dynamic detection conditions. Combined with an illuminance sensor array, it greatly improves the flexibility and efficiency of detection.
[0051] It should be understood that the various forms of processes shown above can be used to reorder, add, or delete steps. For example, the steps described in this invention disclosure can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution disclosed in this invention can be achieved, and this is not limited herein.
[0052] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.
Claims
1. A device for testing the light distribution performance of vehicle headlights, characterized in that: include: Illuminance acquisition device, used to collect illuminance values of vehicle headlights; A positioning device is used to collect the relative pose information between the illuminance acquisition device and the vehicle lights; The detection platform is used to move the illuminance acquisition device and the positioning device. The main control unit is communicatively connected to the illuminance acquisition device, the positioning device, and the detection platform. The illuminance acquisition device includes an illuminance detection and processing device, a sensor motion mechanism, and a first data processor. The sensor motion mechanism is communicatively connected to the first data processor and connected to the illuminance detection and processing device. The sensor motion mechanism receives commands output by the main control mechanism and moves the illuminance detection and processing device to a preset height. The illuminance detection and processing device transmits the illuminance values of the vehicle headlights to the first data processor. The positioning device converts the coordinates in the relative pose information of the obtained spatial position points to a detection coordinate system with the vehicle headlights as the origin, and transmits this information to the first data processor through the main control mechanism. The first data processor reconstructs a two-dimensional light pattern distribution grayscale image based on all coordinates and their corresponding illuminance values, and transmits the two-dimensional light pattern distribution grayscale image to the main control mechanism.
2. The vehicle headlight light distribution performance testing device according to claim 1, characterized in that: The sensor motion mechanism includes a mounting frame, a lead screw, a first drive motor, a lead screw seat, and guide rods. The lead screw is rotatably mounted within the mounting frame, and its bottom end is connected to the first drive motor, which is also located within the mounting frame. The mounting frame is rotatably mounted on the detection platform, and the top end of the lead screw is rotatably connected to the mounting frame. The illuminance detection and processing device is mounted on the lead screw seat, which is threadedly connected to the lead screw. Guide rods are respectively provided on both sides of the lead screw, passing through the lead screw seat and located within the mounting frame. The lead screw seat reciprocates along the length of the guide rods.
3. The vehicle headlight light distribution performance testing device according to claim 2, characterized in that: The mounting bracket includes a mounting plate and two fixing plates. The two fixing plates are respectively fixed to the top and bottom of one side of the mounting plate. The top of the lead screw is rotatably connected to the fixing plate located at the top. The first drive motor is disposed on the fixing plate located at the bottom. The top and bottom of the two guide rods are respectively connected to the two fixing plates.
4. The vehicle headlight light distribution performance testing device according to claim 3, characterized in that: The illuminance detection and processing device includes a substrate, a first illuminance sensor, and a second illuminance sensor. The first illuminance sensor is disposed in the center of the front side of the substrate, and a plurality of second illuminance sensors are disposed on the outer side of the first illuminance sensor. The plurality of second illuminance sensors are uniformly arranged around the first illuminance sensor to form an illuminance sensor array. The first illuminance sensor and the second illuminance sensor transmit the illuminance values of the vehicle headlights they collect to the main control mechanism.
5. The vehicle headlight light distribution performance testing device according to claim 4, characterized in that: The positioning device includes a visual sensor, a lidar, a GPS, and a second data processor. The visual sensor, lidar, and GPS are all mounted on the detection platform. The visual sensor is located in front of the first illuminance sensor, and the GPS is positioned between the visual sensor and the first illuminance sensor. There are two lidars, symmetrically arranged on both sides of the visual sensor. The visual sensor, the two lidars, and the GPS collect relative pose information and transmit it to the second data processor. The second data processor calculates the relative distance and angle based on the received relative pose information.
6. The vehicle headlight light distribution performance testing device according to claim 5, characterized in that: The detection platform includes a detection vehicle, wheels, a second drive motor, a rotating platform, and a third drive motor. There are four wheels, which are symmetrically arranged on the side of the detection vehicle. The second drive motor drives the wheels to rotate. The vision sensor, the lidar, and the GPS are all installed on the detection vehicle. The rotating platform is located in the middle of the top surface of the detection vehicle. The fixed plate at the bottom is installed on the top surface of the rotating platform. The rotating platform is connected to the output end of the third drive motor.
7. The vehicle headlight light distribution performance testing device according to claim 6, characterized in that: The main control mechanism includes a main controller, which is located inside the testing vehicle. The main controller is communicatively connected to the first illuminance sensor, the second illuminance sensor, the first drive motor, the first data processor, the second data processor, the second drive motor, and the third drive motor.
8. A method for testing the light distribution performance of vehicle lamps, using the vehicle lamp light distribution performance testing device according to any one of claims 1-7, characterized in that, Includes the following steps: S1: Start the visual sensor, LiDAR and GPS, and the visual sensor, LiDAR and GPS continuously collect relative pose information; S2: The main controller receives the relative pose information collected in step S1, analyzes the residual of the relative pose information in real time, adjusts the trust weights of the relative pose information collected by the vision sensor, lidar and GPS through the Kalman filter algorithm, and dynamically outputs the relative distance and angle between the detection vehicle and the headlights of the vehicle to be detected. S3: When the relative distance between the test vehicle and the headlight to be tested meets the position specified in the headlight regulations standard library, and the illuminance sensor array is adjusted according to the relative angle with the headlight to be tested, the headlight to be tested is illuminated. S4: The main controller sends an execution detection command to the illuminance acquisition device. The first illuminance sensor and the second illuminance sensor start working after receiving the execution detection command. S5: The main controller has a pre-stored vehicle lamp type information and vehicle lamp regulation standard library. The main controller retrieves the corresponding core test area coordinates from the vehicle lamp type information and vehicle lamp regulation standards according to the input vehicle lamp type. The core test area coordinates are mapped to the relative distance and angle between the test vehicle and the vehicle lamp to be tested in step S2 into the relative motion coordinate system of the test vehicle, and the scanning boundary is obtained. Illuminance and relative pose information are collected within the scanning boundary according to the preset sampling density. S6: The second data processor transforms the coordinates of all spatial positions in the relative pose information to the detection coordinate system with the headlight as the origin, and transmits all coordinates to the first data processor through the main controller; the first data processor reconstructs the preprocessed illuminance values and relative pose information into a continuous two-dimensional light pattern distribution grayscale image using the Kriging interpolation method; and packages the two-dimensional light pattern distribution grayscale image into a complete light pattern data packet; S7: The first data processor uploads the optical data packet to the main controller. The main controller uses the edge detection algorithm in image processing technology to identify the two-dimensional optical distribution grayscale image of the optical data packet, extract the light and dark cutoff lines and form the contour curve to determine the position of the optical boundary. Based on the determined light pattern boundary position, the measured illuminance information corresponding to the light pattern boundary position of the spatial position point specified in the vehicle lighting regulations and standards library on the two-dimensional light pattern distribution grayscale map is extracted, and the measured illuminance information is compared with the illuminance value corresponding to the spatial position point in the vehicle lighting regulations and standards library point by point. The deviation is calculated and quantified. S8: The main controller generates a test report based on the comparative analysis and quantification results in step S7. The test report includes the overall conclusion that it complies with the regulations of the vehicle lighting standards library, the illuminance value deviation data of spatial location points, and a visual light pattern comparison chart.
9. The method for testing the light distribution performance of vehicle lamps according to claim 8, characterized in that: In step S1, the relative pose information includes: GPS uses a Kalman filter algorithm to calculate the absolute position and speed information of the illuminance detection and processing device and the headlights to be detected; The lidar emits a laser beam toward the headlight to be tested and receives the echo, directly measuring the distance to the headlight surface; The vision sensor captures an image containing markers around the headlight to be detected, and the pose data is calculated by matching image feature points and parallax.
10. The method for testing the light distribution performance of vehicle lamps according to claim 8, characterized in that: In step S2, when the relative distance and angle between the main controller's dynamic output test vehicle and the headlight under test do not meet the requirements specified in the headlight regulations standard library, a movement command is generated based on the distance deviation obtained by comparing the relative distance and angle of the headlight under test with the requirements of the headlight regulations standard library. The second drive motor drives the wheels to rotate according to the received movement command, controls the test vehicle to adjust its position, the first drive motor drives the lead screw to rotate, and the third drive motor drives the rotating platform to rotate, thereby realizing the position and orientation adjustment of the illuminance sensor array until the relative distance and angle between the dynamic output illuminance sensor array and the headlight under test meet the requirements specified in the headlight regulations standard library.