Roll-Adjustable Sensor Housing for Precise Camera Alignment
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Solution Overview
Problem
Conventional automotive camera assembly methods face challenges in achieving high angular accuracy due to component tolerances and surface mount technology, leading to misalignment issues during the assembly of lenses, imagers, and housing components.
Innovation Solution
A sensor unit design featuring an angularly adjustable housing with rotatable components, allowing for precise alignment of the imager PCB with the cylindrical lens, and the use of adjustable connectors to accommodate roll movement, enabling accurate angular positioning through a jig or vision system, and fixing the assembly via welding or gluing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional surface mount technology and fixed housing assembly methods are used, then manufacturing simplicity is maintained, but angular accuracy and alignment precision deteriorate due to component tolerances
Solution Approach 1:
The housing is designed with rotational capability about the longitudinal axis, transforming a static assembly into a dynamic one. The sensor subassembly can be rotated to different angular positions during assembly, allowing alignment compensation for cumulative tolerances. This dynamic adjustment capability directly improves angular accuracy without requiring tighter manufacturing tolerances on individual components.
Solution Approach 2:
The camera unit is divided into separable subassemblies: the sensor subassembly (containing imager and lens) and the housing. This segmentation allows independent alignment and adjustment of each subassembly before final assembly, improving overall angular accuracy while maintaining manufacturing simplicity through modular construction.
2Adaptability or versatility
If fixed connector positions are used, then manufacturing simplicity is maintained, but adaptability to different customer requirements and roll tolerance compensation deteriorates
Solution Approach 1:
The housing design with rotatable sensor subassembly provides universal adaptability to meet different customer requirements for connector positions and reference feature orientations. A single housing design can accommodate multiple configurations by simply rotating the sensor subassembly to different angular positions, eliminating the need for multiple specialized housing variants.
Solution Approach 2:
The angular position parameter of the sensor subassembly can be changed during assembly to compensate for roll tolerances and accommodate different customer specifications. This parameter adjustment capability allows the same physical components to meet multiple different requirements without redesign.
3Manufacturing precision
If tight angular tolerances are enforced during assembly, then alignment precision is improved, but assembly time and productivity deteriorate
Solution Approach 1:
The rotatable housing design allows for rapid angular adjustment of the sensor subassembly during assembly. Instead of requiring time-consuming precision alignment procedures, the housing can be rotated to the correct angular position and locked, significantly improving assembly speed while maintaining high alignment precision.
Data Source
AI summary
A sensor unit includes a sensor part and a housing. The housing includes one or more annular surfaces configured to engage with the sensor part at a peripheral mating annular surface thereof. During assembly of the sensor unit, a relative rotatable position of the housing and the sensor part is selectable to align the sensor part with a reference feature of the housing.