Dynamic Illumination Control for Vehicle Gap Measurement

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Solution Overview

Problem

Existing automated gap/height difference measurement systems for vehicles face reliability issues due to variations in vehicle type, color, and gloss, which affect illumination absorption and reflection, making accurate measurements impossible.

Innovation Solution

A system that includes a reflection light sensing unit, a measurement robot, and a controller to automatically control illumination brightness based on the vehicle's color and gloss, using laser illumination and vision sensors to ensure accurate gap and height difference measurements regardless of vehicle type, color, or gloss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated measurement system is used, then productivity is improved, but measurement reliability deteriorates due to illumination absorption and reflection variations

Engineering Contradiction:

Improvemeasurement efficiencyVSAvoidmeasurement reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The illumination intensity is dynamically adjusted based on real-time feedback from light receiving sensors that detect the actual light reflected from the vehicle body. The controller modifies the illumination output to compensate for variations in absorption and reflection caused by different vehicle types, colors, and gloss levels, ensuring consistent measurement reliability across all vehicles while maintaining automated productivity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A feedback control mechanism is implemented where light receiving sensors continuously monitor the illumination reflected from the vehicle body, and the controller uses this feedback signal to automatically adjust the illumination intensity. This closed-loop system ensures that measurement reliability is maintained despite variations in vehicle surface properties, while the automated feedback process preserves high productivity.

Inventive Principle:

Principle #23Feedback

2Device complexity

If fixed illumination intensity is used, then device complexity is reduced, but measurement precision deteriorates due to color and gloss variations

Engineering Contradiction:

Improveillumination control complexityVSAvoidgap and height difference measurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The illumination system performs self-adjustment through an automated feedback mechanism. The light receiving sensors detect the actual reflected light from each vehicle, and the controller automatically modifies the illumination intensity without requiring manual intervention. This self-service approach maintains measurement precision across different vehicle types while adding minimal complexity to the overall system.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If manual inspection is used, then adaptability to different vehicle types is improved, but productivity deteriorates

Engineering Contradiction:

Improveinspection adaptabilityVSAvoidmeasurement throughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The automated measurement system adapts to different vehicle types by dynamically changing the illumination parameter (intensity) based on feedback from light sensors. This parameter adjustment allows the system to compensate for variations in vehicle color, gloss, and absorption characteristics, achieving manual-level adaptability while maintaining automated high-speed measurement throughput.

Inventive Principle:

Principle #35Parameter changes

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 solution improves measurement reliability and productivity by enabling accurate, automatic gap and height difference measurements across various vehicle types without stopping the conveyor line, reducing measurement time and preventing diffused reflection and light intensity shortages.

Implementation Method 1

sensing vehicle body brightness through reflection light reflected depending on illuminance of an illumination from the vehicle body

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

The illumination may include a laser illumination that radiates laser light to the vehicle body

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS9162361B2Gap and height difference measurement system for vehicle and control method of the same

Publication Date: 2015.10.20 HYUNDAI MOTOR CO LTD

AI summary

A gap/height difference measurement system for a vehicle may include a reflection light sensing unit on a the transportation conveyor line and sensing reflection light reflected from the vehicle body transported depending on illuminance of an illumination, a measurement robot measuring the gap and the height difference between the vehicle body and each panel that move while being installed at both sides of the transportation conveyor line in a width direction of the vehicle body at one side spaced from the reflection light sensing unit in a movement direction of the vehicle body, and a controller receiving a signal sensed by the reflection light sensing unit and comparing the received signal with a predetermined value to control the illuminance of the illumination and outputting a specification depending on a vehicle type of the vehicle body transported to the measurement robot to control the measurement robot.