Portable Wheel Aligner With Continuous Rotation Diagnostics
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Solution Overview
Problem
Conventional camera-based 3D machine vision-type aligners are bulky, difficult to move, and prone to inaccurate measurements due to uneven surfaces, vehicle movement, and equipment malfunctions, requiring time-consuming positioning and caster swing procedures, with limited remote control capabilities.
Innovation Solution
A self-contained, portable aligner with self-calibrating cameras on folding arms, continuous measurement capabilities, and advanced analytics for real-time error detection and correction, enabling rapid and accurate alignment without pauses, along with a networked system for remote control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional camera-based aligners are mounted on rigid beams or tall poles to achieve stable measurements, then measurement stability is improved, but portability and ease of movement deteriorate
Solution Approach 1:
The patent applies dynamics by making the camera support structure movable rather than fixed. The camera is mounted on a movable cart with wheels that can be easily transported between alignment bays, while maintaining measurement stability through the cart's design that allows the camera to be positioned at the required height and angle for accurate measurements.
Solution Approach 2:
The patent segments the alignment system into separate portable components: the camera mounted on a movable cart, the console, and the target storage. This segmentation allows each component to be independently moved and positioned, improving portability while maintaining the functional integrity of the measurement system.
2Ease of operation
If camera-based aligners are made portable by using movable mounts, then ease of movement is improved, but measurement precision deteriorates due to positioning errors
Solution Approach 1:
The patent implements feedback through an automated cart positioning system that uses sensors and control algorithms to precisely locate the camera relative to the vehicle. The system continuously monitors the cart's position and makes automatic adjustments to maintain the correct camera-to-vehicle distance and angle, eliminating positioning errors that would otherwise degrade measurement precision.
Solution Approach 2:
The patent replaces manual mechanical positioning with an automated electromechanical positioning system. The cart uses motorized drives and control systems to automatically position itself and the camera, substituting human-operated mechanical adjustment with automated control that provides more consistent and precise positioning.
3Strength
If aligner components are integrated into a single large assembly for stability, then structural rigidity is improved, but maneuverability through crowded shop environments deteriorates
Solution Approach 1:
The patent segments the alignment system into a camera module on a compact cart, a separate console, and modular target storage. This segmentation creates individually maneuverable units that can navigate through crowded shop environments, while each unit maintains sufficient structural rigidity for its specific function.
Solution Approach 2:
The patent applies local quality by designing the cart with selective rigidity: the camera mounting structure is rigid to ensure stable imaging, while the cart frame and wheels are designed for ease of movement. The console and other components have localized rigid elements where needed for stability but maintain overall compactness for maneuverability.
4Measurement precision
If positioning procedures are made rigorous to ensure accurate wheel axis measurement, then measurement accuracy is improved, but procedure time increases
Solution Approach 1:
The patent applies preliminary action by pre-calibrating the camera system and pre-positioning the cart before the actual alignment measurement begins. The system performs initial setup steps including camera focal length calibration, cart wheel circumference measurement, and baseline distance setup in advance, so that the actual wheel axis measurement can proceed quickly without compromising accuracy.
Solution Approach 2:
The patent replaces manual mechanical positioning procedures with automated image-based measurement. Instead of using mechanical gauges and manual measurement tools that require time-consuming adjustment and reading, the system uses the camera to capture images of alignment targets and automatically calculates wheel axis parameters through image processing algorithms.
Data Source
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AI summary
A vehicle wheel alignment system has a plurality of cameras, each camera for viewing a respective target disposed at a respective wheel of the vehicle and capturing image data of the target as the wheel and target are continuously rotated a number of degrees of rotation without a pause. The image data is used to calculate a minimum number of poses of the target of at least one pose for every five degrees of rotation as the wheel and target are continuously rotated the number of degrees of rotation without a pause. At least one of the cameras comprises a data processor for performing the steps of preprocessing the image data, and calculating an alignment parameter for the vehicle based on the preprocessed image data.