Camera Module Reference Surface for Compact Vehicle Mounting
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Solution Overview
Problem
Conventional vehicle on-board cameras require larger clearance between the camera case and windshield due to six-axis adjustment, leading to a larger hood that blocks the field of view, while also being bulkier in size.
Innovation Solution
A camera apparatus with an optical unit comprising a lens barrel portion and a base portion, where the camera substrate is fixed to the optical unit with a reference surface for positioning, allowing for reduced tolerance and smaller size without tilting the lens barrel, thus enabling a smaller hood and camera size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If six-axis adjustment is applied to positioning of the lens barrel relative to the lens barrel holding portion, then the alignment precision between optical axis and image sensor is improved, but the lens barrel may tilt relative to the lens barrel holding portion, requiring larger clearance between camera case and windshield
Solution Approach 1:
The optical unit is divided into two separate components: the lens barrel portion and the base portion. The lens barrel portion holds the lens, while the base portion has a reference surface for positioning. This segmentation allows the lens barrel portion to be fixed to the base portion with a fixed positional relationship, preventing tilting while maintaining alignment precision through the reference surface design.
Solution Approach 2:
The reference surface on the base portion serves as a built-in positioning mechanism that automatically ensures correct alignment between the lens barrel portion and the image sensor when the lens barrel portion is fixed to the base portion. This self-aligning feature eliminates the need for complex six-axis adjustment mechanisms, maintaining precision while reducing clearance requirements.
2Adaptability or versatility
If clearance between camera case and windshield is increased to allow lens barrel tilting, then the alignment flexibility is improved, but the hood size must be increased, blocking more field of view
Solution Approach 1:
By separating the lens barrel portion from the base portion with a defined reference surface, the design achieves alignment flexibility through the fixed positional relationship established by the reference surface, rather than requiring tilting capability. This eliminates the need for increased clearance and allows for a smaller hood that blocks less field of view.
3Manufacturing precision
If lens barrel portion is adjusted by six-axis adjustment relative to base portion, then the optical alignment is improved, but the device complexity and size increase
Solution Approach 1:
The complex six-axis adjustment mechanism is extracted and replaced with a simpler fixed positional relationship established by the reference surface. The lens barrel portion is fixed to the base portion using this reference surface, achieving optical alignment without requiring complex adjustment mechanisms, thereby reducing device complexity while maintaining precision.
Solution Approach 2:
The reference surface acts as a self-aligning feature that automatically ensures correct optical alignment when the lens barrel portion is fixed to the base portion. This eliminates the need for complex six-axis adjustment mechanisms, reducing device complexity while maintaining manufacturing precision through the inherent geometry of the reference surface.
Data Source
AI summary
In a camera apparatus, a camera case is fixed to a windshield from within a cabin of a vehicle. A camera module includes an optical unit and a camera substrate. The optical unit includes a lens. The camera substrate includes an image sensor. The optical unit includes a lens barrel portion and a base portion. The lens barrel portion holds the lens therein. The base portion has a reference surface that serves as a reference for positioning when the camera module is fixed to the camera case and to which the lens barrel portion is fixed so as to have a fixed positional relationship. The camera substrate is fixed to the optical unit in a position in which an optical axis of the lens passes through a center of a light receiving surface of the image sensor and is perpendicular to the light receiving surface of the image sensor.