Mobile Machine Sensor Calibration via Onboard Detection

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Solution Overview

Problem

Existing sensor calibration systems for mobile machines face challenges in maintaining accuracy due to alignment difficulties in worksite settings, time-consuming mechanical adjustments, and reduced productivity when machines need to be taken out of commission for calibration.

Innovation Solution

A sensor calibration system with multiple calibration objects positioned at strategic worksite locations and onboard sensors that use a controller to determine the need for calibration based on task performance, allowing for automatic or manual initiation of calibration operations, even when the machine is in motion, and utilizing transformation algorithms to correct sensor data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the machine is precisely aligned relative to the calibration object, then sensor calibration accuracy is improved, but alignment difficulty and time consumption increase

Engineering Contradiction:

Improvesensor calibration accuracyVSAvoidalignment difficulty

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system uses the machine's own sensors to detect the calibration object and automatically calculate calibration parameters, eliminating the need for manual alignment procedures. The machine autonomously performs calibration by capturing images of the calibration object with its onboard sensors and processing the data to determine sensor parameters.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical alignment procedures with automated optical detection and computational processing. Instead of physically aligning the machine with the calibration object using mechanical guides, the system uses image capture and computer vision algorithms to automatically determine calibration parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If mechanical adjustment of sensor location is performed, then sensor calibration accuracy is improved, but time consumption and cost increase

Engineering Contradiction:

Improvesensor calibration accuracyVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system replaces physical mechanical adjustment of sensor locations with computational correction. Instead of physically moving or repositioning sensors to achieve calibration, the system captures images of the calibration object and uses image processing algorithms to calculate and apply calibration parameters that correct sensor inaccuracies.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the approach from physically adjusting sensor position parameters to mathematically transforming sensor data parameters. The system determines calibration parameters through image processing and applies transformations to sensor outputs, avoiding the need for physical sensor relocation or mechanical adjustment.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the vehicle is taken out of commission for calibration and repairs, then sensor accuracy is maintained, but productivity and efficiency decrease

Engineering Contradiction:

Improvesensor accuracyVSAvoidvehicle productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system enables calibration to be performed during normal vehicle operation without taking the vehicle out of service. The calibration process can be initiated and completed while the vehicle is in commission, allowing continuous productive operation while maintaining sensor accuracy through automated calibration procedures.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The vehicle performs its own calibration autonomously using its onboard sensors and processing capabilities, eliminating the need for external calibration services or taking the vehicle offline. The system self-calibrates by detecting the calibration object and automatically computing correction parameters during normal operation.

Inventive Principle:

Principle #25Self-service

4Productivity

If automated calibration is performed, then calibration speed is improved, but calibration completeness deteriorates

Engineering Contradiction:

Improvecalibration speedVSAvoidcalibration completeness

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system uses a single automated calibration process that simultaneously calibrates multiple sensor types (cameras, LIDAR, RADAR) and multiple sensor parameters (position, orientation, focal length, field of view). The calibration object contains features that enable comprehensive calibration of various sensor properties in one operation, achieving both speed and completeness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8918302B2Machine sensor calibration system

Publication Date: 2014.12.23 CATERPILLAR INC

AI summary

A sensor calibration system for a mobile machine is disclosed. The sensor calibration system may have a first calibration object positioned at a first worksite location, a second calibration object positioned at a second worksite location, and a plurality of sensors located onboard the mobile machine to detect the first and second calibration objects. The sensor calibration system may also have a controller in communication with the plurality of sensors. The controller may be configured to calibrate at least one of the plurality of sensors when the mobile machine is proximate the first worksite location, and to calibrate at least one other of the plurality of sensors when the mobile machine is proximate the second worksite location.