ALIGN TO AN OPTICAL CENTER

Abstract

A system and a method comprise measuring at least one property of the front fender and determining an optical center as a reference target for a headlight based on this at least one property of the front fender. Additionally, an alignment deviation is determined based on the optical center, and the headlight alignment is adjusted to a final alignment target based on this alignment deviation.

Description

AREA OF TECHNOLOGY

[0001] This disclosure generally relates to determining an optical center for a headlight based on an individually measured property of the front fender, which is then used to adjust a headlight alignment. GENERAL STATE OF THE ART

[0002] Vehicles contain many different types of lighting assemblies, such as headlights. These lights must be adjusted during vehicle assembly to ensure that their alignment is within a specified range. SUMMARY

[0003] A method according to an exemplary aspect of the present disclosure includes, among other things: measuring at least one property of the front fender; determining an optical center as a reference target for a headlight based on the at least one property of the front fender; determining an alignment deviation based on the optical center; and adjusting a headlight alignment to a final alignment target based on the alignment deviation.

[0004] In a further non-restrictive embodiment of any method, the method involves adjusting the headlight alignment to a vertical target and a horizontal target located at a predetermined distance from the front of a vehicle.

[0005] In another non-restrictive embodiment of any method, the predetermined distance is approximately twenty-five feet.

[0006] In a further non-restrictive embodiment of any method, the at least one property of the front fender comprises at least a measured distance from the ground to the highest point of a wheel cutout of a front fender.

[0007] In another non-restrictive embodiment of any method, the method involves using a ground clearance measuring device to measure the measured distance.

[0008] In a further non-restrictive embodiment of any method, the ground clearance measuring device comprises at least one camera.

[0009] In a further non-restrictive embodiment of any method, the at least one camera comprises a plurality of cameras and the method includes the following: measuring a first wheel alignment property with a front wheel camera of the plurality of cameras; measuring a second wheel alignment property with a rear wheel camera of the plurality of cameras; measuring a third wheel alignment property with a wheel chamber camera of the plurality of cameras; and measuring the vehicle ground clearance at the highest point of the wheel cutout with a ground clearance camera.

[0010] In a further non-restrictive embodiment of any method, the step of determining the optical center for the headlight includes: determining a vehicle-specific distance from the highest point of the wheel cutout to a designed optical center of an associated vehicle; and adding the vehicle-specific distance to the measured distance to determine the optical center as an optical target center.

[0011] In a further non-restrictive embodiment of any method, the vehicle-specific distance comprises an input which is a predetermined value that is unique for each vehicle, and wherein the measured distance for each vehicle is measured before the headlight alignment is adjusted.

[0012] In a further non-restrictive embodiment of any method, the method involves using the ground clearance measuring device to position the headlight at the optical target center, which was determined on the basis of the vehicle-specific distance and the measured distance, and subsequently adjusting the headlight alignment to the final alignment target based on the alignment deviation.

[0013] In a further non-restrictive embodiment of any method, the alignment deviation comprises an alignment specification based on predetermined vehicle characteristics and a measured ground clearance characteristic.

[0014] In a further non-restrictive embodiment of any method, the method includes measuring the measured distance for a front right fender and a front left fender.

[0015] In a further non-restrictive embodiment of any method, the headlight comprises a front right headlight and a front left headlight and includes the method of setting an alignment for the front right headlight based on the measured distance for the front right fender and setting an alignment for the front left headlight based on the measured distance for the front left fender.

[0016] A system according to an exemplary aspect of the present disclosure includes, among other things: a measuring device that measures at least one property of the front fender; and one or more controls configured to determine an optical center as a reference target for a headlight based on the at least one property of the front fender; to determine an alignment deviation based on the optical center; and to adjust a headlight alignment based on the alignment deviation to a final alignment target.

[0017] In another non-restrictive embodiment of any system, the headlight alignment is adjustable to a vertical target and a horizontal target located at a predetermined distance from the front of a vehicle.

[0018] In a further non-limiting embodiment of any system, the measuring device comprises a ground clearance measuring device, wherein the at least one property of the front fender comprises at least a measured distance from ground level to the highest point of a wheel cutout of a front fender. In a further non-limiting embodiment of any system, the ground clearance measuring device comprises a plurality of cameras, and includes: measuring a first wheel alignment property with a front wheel camera of the plurality of cameras; measuring a second wheel alignment property with a rear wheel camera of the plurality of cameras; measuring a third wheel alignment property with a wheel chamber camera of the plurality of cameras; and measuring the vehicle ground clearance at the highest point of the wheel cutout with a ground clearance camera.

[0019] In a further non-restrictive embodiment of any system, the ground clearance measuring device measures the measured distance for a front right fender and a front left fender, wherein the one or more controllers are configured to set an alignment for a front right headlight based on the measured distance for the front right fender and to set an alignment for a front left headlight based on the measured distance for the front left fender.

[0020] In a further non-restrictive embodiment of any system, the optical center is also determined on the basis of a summation of the measured distance and a vehicle-specific distance from the highest point of the wheel cutout to a designed optical center of the headlight of an associated vehicle, wherein the vehicle-specific distance comprises an input that is a predetermined value unique for each vehicle, and wherein the measured distance is taken for each vehicle before the headlight alignment is adjusted. In a further non-restrictive embodiment of any system, the predetermined distance is approximately twenty-five feet.

[0021] The embodiments, examples, and alternatives described in the preceding paragraphs, the claims, or the following description and drawings, which may include any of their various aspects or individual features, can be considered independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, provided such features are not incompatible. BRIEF DESCRIPTION OF THE FIGURES

[0022] The various features and advantages of the disclosed examples will be apparent to the person skilled in the art from the detailed description. The figures accompanying the detailed description can be briefly described as follows: Fig. Figure 1 illustrates a side view of a vehicle. Fig. Figure 2 is a front view of a measuring device. Fig. Figure 3 is a schematic illustration of the adjustment of headlights to a target height / angle at a predetermined distance from the front of the vehicle. DETAILED DESCRIPTION

[0023] This disclosure describes in detail a system and method for determining an optical center for a headlight based on an individually measured property of the front fender, which is then used to adjust the headlight alignment. With reference to Fig. 1. A vehicle 10 is supported by a plurality of wheels 12 and extends from a front end 14 to a rear end 16. The headlights 18 ( Fig. 1 and Fig. 3) are located at the front end 14 of the vehicle 10. The vehicle 10 includes a front fender 20 on each side, extending downwards from a hood 22 and also extending around the associated wheel 12. Each fender 20 has a cutout 24 that extends in one direction along a length of the vehicle, e.g., a longitudinal direction, from a front fender end 26 near the headlight 18 to a rear fender end 28 near a passenger door opening 30.

[0024] In one example, the cutout 24 includes a curvature, e.g., a curved surface, extending from the front fender end 26 to the rear fender end 28. In some implementations, the rear fender end 28 defines a lowest point of the cutout 24, and a highest point 32 of the cutout 24 is the distance furthest from the ground level 34. In some implementations, a first dimension 36 is measured from the ground level 34 to the lowest point of the cutout 24 at the rear fender end 28, and a second distance 38 is measured from the lowest point of the cutout 24 to the highest point 32 of the cutout 24, e.g., a cutout height. In some implementations, the cutout height can be measured as a single dimension.A third dimension 40 is a known distance from the uppermost point 32 of the cutout 24 to a known optical mean position 42 of the headlight 18. A fourth dimension 56 is a front / rear distance from the known optical mean position 42 of the uppermost point 32 of the cutout 24.

[0025] The present disclosure provides a system and method for: measuring at least one property of the front fender; determining an optical center as a reference target for an associated headlight based on the at least one property of the front fender; applying a predetermined alignment deviation based on the optical center; and adjusting a headlight alignment to a final alignment target with respect to the optical center based on the alignment deviation.

[0026] Current alignment and testing systems in manufacturing facilities have limitations due to the use of a ground-up alignment technique, which creates vehicle styles that are divided into alignment plus ground clearance groups. In some applications, headlight alignment is set to a standard specification at a location 25 feet from the front end of the vehicle. Dividing vehicle styles into groups can lead to reduced efficiency because multiple ground clearances may exist within a style group that must meet a single target specification using the ground-up alignment.

[0027] The present system and method measure a headlight center point and a downward-facing alignment from the optical center, thus eliminating the need for the ground-up alignment technique. In implementations, variables affecting the number of styles would be the headlight type and headlight center point versus a fender cutout position relationship. This would allow headlights of a specific type, plus a specific fender type with an alignment deviation target, to be aligned to the same measured headlight center point. This would significantly reduce complexity and simplify the alignment process.

[0028] Fig. Figure 2 shows an example of a measuring device 44 used in a manufacturing plant to perform various wheel measurements. In one example, the measuring device 44 includes a ground clearance measuring device used at a wheel alignment and headlight alignment station. In implementations, the measuring device 44 includes at least the following: a first camera 46 comprising a front wheel camera that measures a first wheel alignment characteristic; a second camera 48 comprising a rear wheel camera that measures a second wheel alignment characteristic; a third camera 50 comprising a wheel chamber camera that measures a third wheel alignment characteristic; and a fourth camera 52 comprising a vehicle ground clearance measuring camera that measures ground clearance at the fender cutout / wheel arch (32 from Figure 46). Fig. 1) measures for headlight alignment.

[0029] In implementations, the disclosed system and method utilize dimensions from the fender height measuring device in combination with a known designed relationship between the fender and the headlight to calculate the optical center of the headlight 18, which is used as a reference point for a final alignment target for each individual vehicle 10. In one example, one or more controllers 54 are associated with the measuring device 44. The one or more controllers 54 receive measurement data and have access to stored data and vehicle design properties, which are used to calculate the reference point for the final alignment target.

[0030] In implementations, the one or more controllers 54 can include a processor, memory, and one or more input and / or output (I / O) device interfaces communicatively coupled via a local interface. The local interface can include, for example, one or more buses and / or other wired or wireless connections. The controller 54 can be a hardware device for executing software, in particular software stored in memory. The controller 54 can be: a custom-made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors associated with the computing device, a semiconductor-based microprocessor (in the form of a microchip or chipset), or, more generally, any device for executing software instructions.

[0031] The memory can consist of any type or combination of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, VRAM, etc.)) and / or non-volatile memory elements (e.g., ROM, hard disk, tape, CD-ROM, etc.). The software in the memory can consist of one or more separate programs, each containing an ordered list of executable instructions for performing logical functions. Any number of different input / output devices can be connected to one or more I / O interfaces of the system. The controller 54 can be configured to execute software stored in the memory, communicate data to and from the memory, and generally control operations of the computing device according to the software. Software in the memory is read, in whole or in part, by the processor, perhaps buffered within the processor, and then executed.

[0032] As in Fig.As shown in Figure 3, the control unit 54 calculates the optical centers of the right and left headlights 18 using the ground clearance measuring device 44 with respect to fender dimensions. The alignment is set to a predetermined distance (C) from the front end 14 of the vehicle. In this example, the predetermined distance (C) is twenty-five feet. In other examples, other predetermined distances may be used depending on other alignment specifications. An average calculated optical center (D) is used as the height of the optical center for both headlights 18, e.g., the reference target point, so that the vehicle 10 performs symmetrical alignment. The headlight alignment is thus set to a vertical target and a horizontal target located at the predetermined distance.In this example, an alignment deviation (A) is calculated from design requirements by determining the best headlight alignment for performance based on the height (D) of the optical center to obtain a desired alignment limit target (B). This target deviation (A) is subtracted from the calculated optical center (D) to arrive at the final alignment target (B). In implementations, the adjustment might involve setting the alignment downwards at a specific angle from the reference target plane to the set final target plane.

[0033] In implementations, inputs to the system include at least a predefined optical center for each vehicle headlight type; a distance between the uppermost section of a fender wheel cutout and the optical center; and a headlight alignment specification with calculations based on the headlight's optical center. In these implementations, each headlight consists of a plurality of LED luminaires, and the optical center is calculated based on the plurality of LED luminaires combined. A person skilled in the art, benefiting from this description, is able to determine the optical center that would be used for these purposes. The distance between the uppermost section of a fender wheel cutout and the determined optical center is a known value for each type of vehicle layout configuration.

[0034] In one example, each vehicle would enter an alignment station within a manufacturing plant, where the aforementioned associated inputs for that vehicle would be identified. This would identify the vehicle type, the light type, and defined geometric constants of the front X / Z fender. As is known, the X direction refers to a direction along the length of a vehicle, the Y direction refers to a direction along the width of the vehicle, and the Z direction refers to a direction along the height of the vehicle.

[0035] Next, the measuring device 44 measures defined vehicle characteristics and then uses the defined vehicle geometry to calculate the vertical and horizontal coordinates of the headlight center position. For example, the measuring device 44 uses the fourth camera 52 to measure dimensions from the ground to the wheel arch of the front fender for each side, and the controller 54 then calculates the position of the headlight's optical center in the Y / Z directions based on the known geometry design constants for this vehicle type.

[0036] The measuring device 44 then positions itself relative to a horizontal coordinate (Y) (considered constant from a vehicle center point) and to the calculated (Z) vertical coordinate. In implementations, this Y / Z position includes a reference target point.

[0037] Next, using the system inputs and the measured geometry, the system determines a nominal vertical and horizontal target position for each headlight. In one example, the system calculates the nominal vertical and horizontal targets for this vehicle type by applying a given alignment deviation value to the calculated vertical headlight center point position (Z), e.g., the target point, to determine the nominal vertical alignment target. The nominal horizontal target is a constant Y-value, specific to the vehicle type, and a constant distance from the vehicle center.

[0038] Finally, an operator and / or equipment is used to adjust the headlights to the calculated vertical (Z) and horizontal (Y) targets. For example, the headlights are adjusted at their vertical limits to the calculated final V and H target values.

[0039] The preceding description is exemplary and not limiting. Variations and modifications of the disclosed examples may be apparent to a person skilled in the art, which do not necessarily deviate from the core of this disclosure. Therefore, the scope of protection granted by this disclosure can only be determined by reading the following patent claims.

[0040] According to the present invention, a method comprises: measuring at least one property of the front fender; determining an optical center as a reference target for a headlight based on the at least one property of the front fender; determining an alignment deviation based on the optical center; and adjusting a headlight alignment to a final alignment target based on the alignment deviation.

[0041] In one aspect of the invention, the method involves adjusting the headlight alignment to a vertical target and a horizontal target located at a predetermined distance from the front of a vehicle.

[0042] In one aspect of the invention, the predetermined distance is approximately twenty-five feet.

[0043] In one aspect of the invention, the at least one feature of the front fender comprises at least a measured distance from the ground to the highest point of a wheel cutout of a front fender.

[0044] In one aspect of the invention, the method involves using a ground clearance measuring device to measure the measured distance.

[0045] In one aspect of the invention, the ground clearance measuring device comprises at least one camera.

[0046] In one aspect of the invention, the at least one camera comprises a plurality of cameras, and includes: measuring a first wheel alignment characteristic with a front wheel camera of the plurality of cameras; measuring a second wheel alignment characteristic with a rear wheel camera of the plurality of cameras; measuring a third wheel alignment characteristic with a wheel chamber camera of the plurality of cameras; and measuring the vehicle ground clearance at the highest point of the wheel cutout with a ground clearance camera.

[0047] In one aspect of the invention, determining the optical center for the headlight involves: determining a vehicle-specific distance from the highest point of the wheel cutout to a designed optical center of an associated vehicle; and adding the vehicle-specific distance to the measured distance to determine the optical center as an optical target center.

[0048] In one aspect of the invention, the vehicle-specific distance comprises an input which is a predetermined value that is unique for each vehicle, and wherein the measured distance for each vehicle is measured before the headlight alignment is adjusted.

[0049] In one aspect of the invention, the method involves using the ground clearance measuring device to position the headlight at the optical target center, which was determined on the basis of the vehicle-specific distance and the measured distance, and subsequently adjusting the headlight alignment to the final alignment target based on the alignment deviation.

[0050] In one aspect of the invention, the alignment deviation comprises an alignment specification based on predetermined vehicle characteristics and a measured ground clearance characteristic.

[0051] In one aspect of the invention, the method involves measuring the measured distance for a front right fender and a front left fender.

[0052] In one aspect of the invention, the headlight comprises a front right headlight and a front left headlight, and includes adjusting an alignment for the front right headlight based on the measured distance for the front right fender and adjusting an alignment for the front left headlight based on the measured distance for the front left fender.

[0053] According to the present invention, a system is provided comprising: a measuring device that measures at least one property of the front fender; and one or more controllers configured to determine an optical center as a reference target for a headlight based on the at least one property of the front fender; to determine an alignment deviation based on the optical center; and to adjust a headlight alignment based on the alignment deviation to a final alignment target.

[0054] According to one embodiment, the headlight alignment is adjustable to a vertical target and a horizontal target located at a predetermined distance from the front of a vehicle.

[0055] According to one embodiment, the measuring device comprises a ground clearance measuring device and wherein the at least one property of the front fender comprises at least a measured distance from a ground level to the highest point of a wheel cutout of a front fender.

[0056] According to one embodiment, the ground clearance measuring device comprises a plurality of cameras, and includes: measuring a first wheel alignment characteristic with a front wheel camera of the plurality of cameras; measuring a second wheel alignment characteristic with a rear wheel camera of the plurality of cameras; measuring a third wheel alignment characteristic with a wheel chamber camera of the plurality of cameras; and measuring the vehicle ground clearance at the highest point of the wheel cutout with a ground clearance camera.

[0057] According to one embodiment, the ground clearance measuring device measures the measured distance for a front right fender and a front left fender, wherein the one or more controllers are configured to set an alignment for a front right headlight based on the measured distance for the front right fender and to set an alignment for a front left headlight based on the measured distance for the front left fender.According to one embodiment, the optical center is also determined on the basis of a summation of the measured distance and a vehicle-specific distance from the uppermost point of the wheel cutout to a designed optical center of the headlight of an associated vehicle, wherein the vehicle-specific distance includes an input which is a predetermined value that is unique for each vehicle, and wherein the measured distance is measured for each vehicle before the headlight alignment is adjusted.

[0058] According to one embodiment, the predetermined distance is approximately twenty-five feet.

Claims

[1] Procedure, encompassing: Measuring at least one property of the front fender; Determining an optical center as a reference target for a headlight based on at least one property of the front fender; Determining an alignment deviation based on the optical center; and Adjusting a headlight alignment to a final alignment target based on the alignment deviation. [2] Method according to claim 1, comprising adjusting the headlight alignment to a vertical target and a horizontal target located at a predetermined distance from the front of a vehicle, wherein the predetermined distance is optionally approximately twenty-five feet. [3] Method according to claim 1, wherein the at least one feature of the front fender comprises at least a measured distance from the ground to a topmost point of a wheel cutout of a front fender. [4] Method according to claim 3, comprising using a ground clearance measuring device to measure the measured distance, and wherein the ground clearance measuring device comprises at least one camera. [5] Method according to claim 4, wherein the at least one camera comprises a plurality of cameras, and comprising: Measuring a first wheel alignment characteristic with a front wheel camera of the multitude of cameras; Measuring a second wheel alignment characteristic with a rear wheel camera of the multiple cameras; Measuring a third wheel alignment characteristic with a wheel chamber camera of the plurality of cameras; and Measuring the vehicle ground clearance at the highest point of the wheel arch using a ground clearance camera. [6] The method of claim 4, wherein determining the optical center for the headlight comprises the following: Determining a vehicle-specific distance from the highest point of the wheel arch to a defined optical center of an associated vehicle; and Adding the vehicle-specific distance to the measured distance to determine the optical center as an optical target center. [7] Method according to claim 6, wherein the vehicle-specific distance comprises an input which is a predetermined value which is unique for each vehicle, and wherein the measured distance for each vehicle is measured prior to adjusting the headlight alignment, and comprising using the ground clearance measuring device to position the headlight at the optical target center which was determined on the basis of the vehicle-specific distance and the measured distance, and subsequently adjusting the headlight alignment to the final alignment target on the basis of the alignment deviation. [8] Method according to claim 7, wherein the alignment deviation comprises an alignment specification based on predetermined vehicle characteristics and a measured ground clearance characteristic. [9] Method according to claim 4, comprising measuring the measured distance for a front right fender and a front left fender, and wherein the headlight comprises a front right headlight and a front left headlight, and comprising adjusting an alignment for the front right headlight based on the measured distance for the front right fender and adjusting an alignment for the front left headlight based on the measured distance for the front left fender. [10] System, encompassing: a measuring device that measures at least one property of the front fender; and one or more controllers configured to do the following: Determining an optical center as a reference target for a headlight based on at least one property of the front fender; Determining an alignment deviation based on the optical center; and Adjusting a headlight alignment to a final alignment target based on the alignment deviation. [11] System according to claim 10, wherein the headlight alignment is adjustable to a vertical target and a horizontal target located at a predetermined distance from the front of a vehicle. [12] System according to claim 11, wherein the measuring device comprises a ground clearance measuring device and wherein the at least one property of the front fender comprises at least a measured distance from a ground level to a topmost point of a wheel cutout of a front fender. [13] System according to claim 12, wherein the ground clearance measuring device comprises a plurality of cameras, and comprising: Measuring a first wheel alignment characteristic with a front wheel camera of the multitude of cameras; Measuring a second wheel alignment characteristic with a rear wheel camera of the multiple cameras; Measuring a third wheel alignment characteristic with a wheel chamber camera of the plurality of cameras; and Measuring the vehicle ground clearance at the highest point of the wheel arch using a ground clearance camera. [14] System according to claim 12, wherein the ground clearance measuring device measures the measured distance for a front right fender and a front left fender and wherein the one or more controllers are configured to set an alignment for a front right headlight based on the measured distance for the front right fender and to set an alignment for a front left headlight based on the measured distance for the front left fender. [15] System according to claim 12, wherein the optical center is also determined on the basis of a summation of the measured distance and a vehicle-specific distance from the uppermost point of the wheel cutout to a designed optical center of the headlight of an associated vehicle, and wherein the vehicle-specific distance comprises an input which is a predetermined value which is unique for each vehicle, and wherein the measured distance for each vehicle is measured before the headlight alignment is adjusted, and wherein the predetermined distance is optionally approximately twenty-five feet.

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