Modular Tread Depth Reader With Sealed Self-Calibrating Sensors
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Solution Overview
Problem
Existing tire wear measurement systems face challenges such as obsolescence of electronic hardware, sensor deformation, laser misalignment, and water ingress, which affect the accuracy and durability of tread depth measurement.
Innovation Solution
A modular sensor unit-based tread depth reader with improved sealing capabilities and a daisy chain configuration that minimizes load forces and vibrations, eliminates the need for laser calibration between units, and uses ultrasonics, radar reflectivity, or laser triangulation to capture tire tread images for precise depth measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional non-modular sensor systems are used, then initial measurement capability is provided, but hardware obsolescence and sensor deformation occur over time reducing reliability
Solution Approach 1:
The sensor system is divided into independent modular sensor units that can be individually replaced. Each module contains its own sensor, housing, and mounting structure, allowing selective replacement of only the worn or obsolete module rather than the entire system, thereby extending overall system lifespan while maintaining measurement accuracy.
Solution Approach 2:
The modular design allows updating sensor parameters and technologies independently. When sensors become obsolete or deform over time, individual modules can be replaced with updated versions featuring improved sensor parameters, maintaining measurement reliability while extending system operational duration.
2Measurement precision
If multiple sensor units are installed to cover full tire tread, then comprehensive measurement is achieved, but laser calibration between units becomes complex
Solution Approach 1:
Each modular sensor unit is equipped with its own integrated laser source and sensor pair, forming self-contained measurement systems. The units independently perform laser triangulation without requiring inter-unit calibration, as each module self-calibrates using its own reference features, dramatically simplifying the deployment process while maintaining comprehensive tread measurement coverage.
3Ease of operation
If sensor units are exposed to road environment, then direct tire measurement is enabled, but water ingress and contamination damage sensors
Solution Approach 1:
Each modular sensor unit is enclosed in a sealed protective housing that prevents water and contamination ingress while allowing optical signals to pass through. The housing acts as a protective barrier that shields sensitive sensors from road environment hazards, enabling direct tire measurement without exposing components to damaging elements.
Solution Approach 2:
The sealed housing serves as an intermediary structure between the harsh road environment and the sensitive sensor components. It transmits necessary optical signals while blocking harmful water and contaminants, allowing the sensors to operate in protected conditions while maintaining direct measurement capability.
4Measurement precision
If heavy loading forces are applied during tire measurement, then accurate footprint capture is achieved, but sensor body deformation occurs
Solution Approach 1:
The measurement function is extracted from the sensor electronics and placed in the rigid housing structure. The housing bears the full loading forces and vibrations from tire contact, while the sensitive sensor components remain isolated in a protected environment, preventing deformation while maintaining accurate footprint capture capability.
Solution Approach 2:
The robust housing structure acts as an intermediary that absorbs and withstands mechanical loading forces and vibrations. It protects the internal sensor components from direct exposure to these forces, preventing deformation while enabling accurate measurement of tire footprint under heavy loading conditions.
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
The system provides accurate, durable, and efficient tread depth measurement by reducing interference and enhancing sensor protection, allowing for easy installation and calibration-free operation, thus improving tire wear monitoring.
Implementation Method 1
ultrasonics, radar reflectivity or other optical methods, such as laser triangulation or light section processes
Implementation Method 2
ultrasonics, radar reflectivity or other optical methods
Implementation Method 3
ultrasonics, radar reflectivity or other optical methods
Data Source
Figure 1
Figure 2A~2B
Figure 2C
AI summary
A system and method for estimating a tread depth of a tire (106) supporting a vehicle (100) is disclosed. The system comprises a tread depth reader housing (136) and a plurality of modular sensor units (127) disposed within the tread depth reader housing (136). Individual modular sensor units comprise a light source (145), a sensor (142) and modular sensor unit control circuitry (148). A first color of the light source (145) of a first modular sensor unit (127a) differs from a second color of the light source (145) of a second modular sensor unit (127b). The first modular sensor unit (127a) is directly adjacent to the second modular sensor unit (127b).