Multi-Spot Soldering for Camera-LiDAR Parallel Alignment
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Solution Overview
Problem
The existing asynchronous soldering methods for cameras and laser radars fail to maximize the parallel relationship between lens and sensor, leading to poor reliability and imaging effects due to temperature and humidity issues, and lack solder and temperature compensation.
Innovation Solution
A multi-spots soldering method involving position-determining, solder-control, and soldering energy compensation techniques, where soldering spots form a regular polygon and are adjusted in real-time using thermal imaging, ensuring equivalent solder distribution and maintaining components parallel, with accuracy detection and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If asynchronous soldering method is used to solder lens and sensor one by one, then the soldering process can be completed with simple equipment, but the parallel relationship between lens and sensor cannot be maximized and reliability is low
Solution Approach 1:
The invention divides the bonding process into multiple independent soldering spots (first, second, third, and fourth soldering spots) arranged at specific positions around the lens and sensor. This segmentation allows simultaneous soldering at multiple locations, improving both reliability through distributed bonding points and maintaining process simplicity through standardized spot placement patterns.
Solution Approach 2:
The invention merges multiple soldering operations into a single simultaneous process. By positioning multiple soldering spots around the lens and sensor and applying soldering energy concurrently to all spots, the system achieves enhanced bonding reliability while reducing total process time, effectively combining what would otherwise be sequential operations.
2Ease of manufacture
If optical adhesive is used to stick lens to sensor, then the bonding process is simplified, but the connection is affected by temperature and humidity causing poor reliability
Solution Approach 1:
The invention replaces the chemical bonding mechanism of optical adhesives with a thermal-mechanical soldering process. By using soldering energy to melt and solidify solder material at multiple designated spots, the system achieves temperature-compensated bonding that is not susceptible to humidity effects, thereby improving connection stability while maintaining ease of manufacture through a controlled thermal process.
Solution Approach 2:
The invention employs temperature compensation by dynamically adjusting soldering energy parameters based on real-time temperature detection at each soldering spot. This ensures consistent bonding quality across varying environmental conditions, replacing the temperature and humidity sensitivity of adhesive bonding with a controlled thermal process that maintains reliability.
3Reliability
If multiple soldering spots are used to solder lens and sensor simultaneously, then the parallel relationship is maximized and reliability is improved, but the soldering process complexity increases
Solution Approach 1:
The invention positions the multiple soldering spots asymmetrically relative to the optical axis, with specific spots located at different radial distances and angular positions. This asymmetric arrangement optimizes the parallel relationship between lens and sensor while distributing thermal loads effectively, achieving high reliability without requiring complex symmetric positioning mechanisms.
Solution Approach 2:
The invention incorporates real-time temperature detection at each soldering spot and uses this feedback to dynamically adjust soldering energy application. This closed-loop control simplifies the overall process by automatically compensating for variations, eliminating the need for complex manual adjustment mechanisms while maintaining high bonding reliability.
4Manufacturing precision
If soldering energy is increased to compensate for heat loss at multiple spots, then the soldering quality is improved, but the energy consumption and risk of overheating increase
Solution Approach 1:
The invention applies soldering energy locally at each designated spot rather than uniformly across the entire bonding interface. Each soldering spot receives energy independently based on its specific thermal characteristics and distance from the heat source, improving soldering quality consistency while minimizing total energy consumption by avoiding unnecessary heating of non-bonding areas.
Solution Approach 2:
The invention dynamically adjusts the soldering energy applied to each spot based on real-time temperature detection. The system continuously monitors temperature at each soldering spot and modulates energy input accordingly, preventing overheating while ensuring adequate heating for quality bonding. This dynamic control optimizes energy efficiency while maintaining consistent soldering quality across all spots.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the reliability and service life of camera and laser radar components by ensuring consistent soldering quality, parallel alignment, and adaptability to different materials, improving accuracy and process control.
Implementation Method 1
the energy of the soldering spots are detected in real time via a thermal imaging camera to obtain real-time data
Implementation Method 2
a multi-spots soldering method for processing a camera and a laser radar
Data Source
AI summary
A multi-spots welding method for processing a camera and a laser radar includes a position-determining method of welding spots, a solder-control method and a welding energy compensation method; the position-determining method of welding spots includes providing a plurality of welding spots between a first weldment and a second weldment; the solder-control method includes adding equivalent amount of solder on the plurality of welding spots according to a preset amount of the solder; and the welding energy compensation method includes detecting energy of the plurality of welding spots in real time when the plurality of welding spots are welded simultaneously, comparing detected real-time data of the plurality of welding spots with the preset amount of the solder.