Sensor Apparatus Datum Feature Alignment
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Solution Overview
Problem
The alignment of vehicle sensors is challenging due to variability in manufacturing and assembly processes, leading to significant location and orientation errors, which complicates installation and calibration, making it time-consuming and expensive.
Innovation Solution
A prefabricated sensor assembly with precalibrated sensors and feature-locating elements that fit into a vehicle roof mount, utilizing datum features to align sensors accurately, reducing variability and simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors are installed and calibrated individually to achieve accurate alignment, then sensor alignment precision is improved, but installation time and manufacturing complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-calibrating sensors within a sensor assembly before installation. The sensor assembly is pre-configured with multiple sensors positioned at predetermined locations and orientations, and pre-calibrated to account for their specific positions. This allows the entire assembly to be installed as a single unit without requiring individual calibration of each sensor during installation, thereby maintaining alignment precision while significantly reducing installation time.
2Ease of manufacture
If conventional manufacturing and assembly processes are used, then manufacturing simplicity is maintained, but sensor location variability increases
Solution Approach 1:
The patent applies segmentation by dividing the sensor system into two distinct parts: a sensor assembly containing multiple pre-positioned and pre-calibrated sensors, and a vehicle body. The sensor assembly is manufactured as a separate unit with controlled internal tolerances, and then installed as a complete unit on the vehicle. This segmentation allows for precise sensor positioning within the assembly while simplifying the overall manufacturing process by avoiding the need to coordinate multiple components during final assembly.
3Adaptability or versatility
If multiple components with individual tolerances are assembled, then manufacturing flexibility is maintained, but cumulative location error increases
Solution Approach 1:
The patent applies merging by combining multiple sensors into a single integrated sensor assembly where the cumulative tolerance of all components is controlled as a unified unit. Rather than assembling multiple separate components each with individual tolerances, the sensors are mounted on a common base or housing structure within the assembly, allowing the entire assembly to be manufactured and calibrated together. This reduces cumulative location error while maintaining manufacturing flexibility through modular design.
Data Source
AI summary
A vehicle roof mount includes at least one datum feature. The datum feature is provided according to at least one datum. The at least one datum is determined according to a specified orientation of a sensor included in a sensor frame. The sensor frame is mateable to the roof mount.