Automotive Camera Housing Step Alignment for Lens Assembly Precision
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Solution Overview
Problem
Automotive cameras face challenges in maintaining accurate alignment of housing parts due to tolerances, which can affect image quality and the robustness of the connection process.
Innovation Solution
The design incorporates a step structure around the lens opening with four side faces oriented away from the lens opening, allowing for a lateral contact between the second housing part and two perpendicular side faces, ensuring accurate alignment during manufacturing and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional housing connection methods are used, then manufacturing simplicity is maintained, but alignment precision between housing parts deteriorates due to tolerances
Solution Approach 1:
The flange is segmented into four distinct side faces forming a step structure, with each face serving as an independent alignment reference. This segmentation allows the second housing part to contact multiple precise reference surfaces, improving alignment precision while maintaining manufacturing feasibility through modular design
Solution Approach 2:
The alignment mechanism transitions from a single-plane contact interface to a multi-dimensional step structure with four side faces. By adding the vertical dimension (step height) to the horizontal alignment faces, the patent creates a three-dimensional alignment system that enhances precision without significantly increasing overall structural complexity
2Manufacturing precision
If tight tolerances are applied to all side faces, then alignment accuracy is improved, but manufacturing difficulty increases
Solution Approach 1:
Different tolerance levels are applied to different side faces of the step structure. The first and second side faces that contact the second housing part are manufactured with tight tolerances for precise alignment, while the third and fourth side faces can have looser tolerances. This local differentiation of quality requirements improves alignment accuracy at critical interfaces while reducing overall manufacturing difficulty
Solution Approach 2:
The step structure introduces asymmetry in the flange design, with the first and second side faces serving as primary alignment references and the third and fourth faces as secondary or non-contact surfaces. This asymmetric functional assignment allows selective application of manufacturing precision, focusing tight tolerances only where needed for alignment while accepting looser tolerances elsewhere
Data Source
AI summary
An automotive camera (2) comprises a first housing part (5) and a lens unit (4), which is connected to the first housing part (5) at a lens opening (10) and a second housing part (8), which is connected to the first housing part (5) at a flange (6) of the first housing part (5), which surrounds the lens opening (10) forming a step structure (9) comprising four side faces (11a, 11b, 12a, 12b), which are oriented away from the lens opening (10). The second housing part (8) is in contact with a first side face (11a) of the four side faces (11a, 11b, 12a, 12b) and the second housing part (8) is in contact with a second side face (11b) of the four side faces (11a, 11b, 12a, 12b), which is perpendicular to the first side face (11a).