Automotive Sensor Alignment Using Optical Pose Calibration
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Solution Overview
Problem
Current machine vision-based vehicle alignment systems are inefficient for large vehicles due to size constraints and require extensive hardware, including rigid beams and additional cameras, which are costly and obstructive, and lack the ability to quickly measure alignment without stopping the vehicle.
Innovation Solution
A vehicle alignment system using a fixture with image sensors and a data processor to calculate the pose of targets and generate instructions for positioning, eliminating the need for rigid beams and additional hardware by measuring drive direction and gravity direction to align wheels without direct lateral position or orientation information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional camera-based aligners use rigid beams to connect cameras, then the relative position and orientation of cameras can be determined, but the system becomes expensive, structurally obstructive, and requires extensive hardware
Solution Approach 1:
The patent removes the rigid beam structure from the system entirely. Instead of using physical beams to connect cameras, the system uses a separate camera/target system to continuously calibrate camera positions through optical measurement, extracting the position determination function from mechanical structure to optical measurement
Solution Approach 2:
The patent introduces a calibration target as an intermediary element. The target is viewed by multiple cameras to establish geometric relationships and calculate camera positions and orientations indirectly through coordinate transformation, rather than requiring direct physical connection between cameras
2Measurement precision
If conventional aligners use additional cameras to measure across the vehicle, then camera calibration is achieved, but the system requires expensive components and structures that get in the way
Solution Approach 1:
The patent extracts the calibration function from the main measurement cameras and implements it through a separate, dedicated camera/target system. This separate system can be positioned independently without interfering with the primary alignment measurement process or shop operations
Solution Approach 2:
Instead of using cameras to directly measure across the vehicle, the system inverts the approach by using a camera to view a target that is itself viewed by the measurement cameras. This indirect measurement approach achieves calibration without requiring direct line-of-sight measurements between measurement cameras
3Measurement precision
If conventional aligners require positioning and steering swing procedures, then alignment measurements are obtained, but the process is time-consuming and requires the technician to hold the vehicle steady at certain points
Solution Approach 1:
The patent implements continuous measurement capability where the camera system continuously tracks the target and calculates alignment parameters in real-time as the vehicle moves through the positioning procedure. The system processes image data continuously to calculate pose information without requiring pauses or stops in the measurement process
Solution Approach 2:
The system incorporates real-time feedback through continuous image capture and processing. The camera system continuously monitors target position and provides immediate feedback on alignment parameters, allowing the vehicle to be moved continuously rather than requiring it to be held steady at discrete measurement points
Data Source
AI summary
Systems and methods are disclosed for calibrating and aligning automotive sensors, such as advanced driver assistance system (ADAS) sensors. Embodiments include a system having an image sensor mounted on a fixture in a known pose relative to the fixture. The image sensor is for viewing a target disposed on a vehicle and having a known pose relative to the vehicle, and for capturing image data of the target. A data processor is provided for performing the steps of calculating, using the image data, a pose of the target; calculating a pose of the image sensor relative to the vehicle using the calculated pose of the target; and generating instructions for positioning the fixture at a predetermined pose relative to the vehicle using the calculated pose of the image sensor relative to the vehicle.