Sensor Enclosure Thermal Management via Adaptive Fan Control
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Solution Overview
Problem
Autonomous vehicle sensors face operational challenges due to harsh environmental conditions, such as extreme temperatures and moisture, which can lead to malfunction and render the vehicle inoperable, and are also vulnerable to damage from road debris.
Innovation Solution
A system comprising a sensor enclosure with a fan and controller that regulates fan speed based on vehicle speed, internal and external temperatures, and moisture levels, along with vents and a moisture detector to manage airflow and prevent moisture ingress, while also incorporating a filter to prevent debris entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are mounted exterior to the vehicle, then the sensors can provide accurate sensor data for autonomous vehicle operations, but the sensors are exposed to harsh environmental elements and road debris which can prematurely shorten their lifetimes and increase the risk of impact damage
Solution Approach 1:
The patent applies this principle by using a sensor enclosure with a transparent cover ( dome structure) that protects the sensors from environmental elements and debris while allowing optical signals to pass through. The enclosure acts as a protective shell that shields sensors from rain, dust, UV radiation, and road debris impacts.
Solution Approach 2:
The patent creates a controlled internal environment within the sensor enclosure that is isolated from harsh external conditions. The enclosure maintains a stable internal atmosphere protected from external environmental factors, effectively creating an inert environment for the sensors.
2Object-affected harmful factors
If sensors are encased in a sensor enclosure, then the sensors are protected against environmental elements and road debris, but the internal temperature of the enclosure may reach beyond operational temperature ranges for the sensors
Solution Approach 1:
The patent extracts heat from the sensor enclosure interior by introducing airflow through vents and using active cooling mechanisms. The cooling system removes excess heat from the enclosed space, separating the thermal management function from the protective enclosure structure.
Solution Approach 2:
The patent uses pneumatic principles by introducing airflow through vents in the enclosure and using fans to circulate air for cooling purposes. The airflow system manages internal temperature by convective heat transfer through the enclosure volume.
3Object-affected harmful factors
If a sensor enclosure is used to protect sensors, then additional protection is provided, but moisture inside the enclosure can condensate or fog up, thereby preventing the sensors from gathering critical road information
Solution Approach 1:
The patent extracts moisture from the sensor enclosure interior by introducing airflow that passes through moisture-absorbing materials or directly removes humid air through ventilation. This prevents moisture accumulation and condensation on the optical surfaces.
Solution Approach 2:
The patent employs porous moisture-absorbing materials within the enclosure to passively or actively remove moisture from the internal atmosphere. These materials absorb excess humidity to prevent condensation and fogging on the sensor optical paths.
4Temperature
If vents are added to the enclosure for heat exchange, then temperature control is improved, but the risk of moisture ingress and debris entry increases
Solution Approach 1:
The patent applies different properties to different parts of the ventilation system. Vents are positioned and designed with specific characteristics (such as location, size, and protective features) to allow heat exchange while minimizing moisture and debris ingress. The filter system has localized high-density filtering at intake points.
Solution Approach 2:
The patent uses composite structures for the enclosure and vent systems that combine protective and functional properties. The enclosure integrates protective features (filters, hydrophobic coatings) with ventilation functions, creating a composite system that manages both thermal exchange and environmental protection.
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 effectively maintains optimal operating conditions for sensors, preventing malfunctions due to temperature and moisture issues and protecting them from debris, ensuring reliable autonomous vehicle operation.
Implementation Method 1
a fan disposed at a base of the enclosure... regulating a rotation speed of the fan... airflow into the enclosure
Implementation Method 2
a second vent disposed at a top surface of the enclosure configured to allow heat to escape
Implementation Method 3
a moisture absorbent disposed at the second vent
Data Source
AI summary
Provided herein is a system and method for cooling a sensor enclosure of a vehicle. The system comprises one or more sensors configured to determine a speed of the vehicle, an internal temperature of an enclosure, and an external temperature. The system comprises an enclosure to house the one or more sensors. The system comprises a fan disposed at a base of the enclosure. The system comprises a controller configured to regulate a rotation speed of the fan based on the speed of the vehicle, the internal temperature of the enclosure, the external temperature, or the difference between the internal temperature of the enclosure and the external temperature. The controller operates the fan at the regulated rotation speed.