Sensor Housing Forced Convection Cooling
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Solution Overview
Problem
Autonomous driving sensors mounted externally on vehicles do not benefit from the temperature regulation provided by the vehicle's HVAC system, necessitating effective methods for maintaining them within fixed temperature ranges.
Innovation Solution
A system utilizing a mounting bracket assembly with ducting to channel conditioned air from the vehicle's cabin to a heat sink, coupled with a fan to convectively dissipate heat from the sensor, ensuring temperature regulation of exterior-mounted sensors like LiDAR sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are mounted externally on the vehicle, then the sensors can detect objects in the surroundings effectively, but the sensors are exposed to unregulated temperatures and cannot benefit from the vehicle's HVAC system
Solution Approach 1:
The sensor housing is divided into separate functional sections: a sensor mounting section, a heat sink section, and a ducting system. This segmentation allows the sensor to be isolated from ambient temperature extremes while maintaining external mounting benefits for detection capability.
Solution Approach 2:
A thermally conductive housing acts as an intermediary between the sensor and the external environment. The housing includes insulation materials that mediate thermal transfer, protecting the sensor from direct exposure to unregulated external temperatures while allowing the sensor to remain externally mounted.
2Temperature
If a cooling system is added to regulate sensor temperature, then the sensor can maintain operational temperature, but the device complexity increases
Solution Approach 1:
The cooling functionality is merged into the sensor housing itself rather than being a separate system. The housing combines structural support, thermal insulation, and active cooling components (heat sink, ducting, fan) into a single integrated assembly, reducing overall system complexity.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides mechanical support for the sensor, acts as a thermal insulator, functions as a heat sink, and includes integrated ducting for air flow. This multi-functionality eliminates the need for separate cooling components.
3Temperature
If a heat sink with ducting is integrated into the sensor housing, then heat can be dissipated convectively, but the manufacturing complexity increases
Solution Approach 1:
The ducting system is nested within the housing structure, with air channels integrated into the housing walls. The heat sink is nested within the housing, and the fan is positioned within the same assembly. This nesting approach allows complex cooling functionality to be achieved without proportionally increasing manufacturing complexity.
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
Effectively maintains the operational temperature of exterior-mounted sensors, enhancing their performance and reliability in various environmental conditions.
Implementation Method 1
a fan configured to draw air from within a cabin area of the vehicle, push the air through the ducting and across the heat sink
Implementation Method 2
a heat sink coupled to a base of the enclosure and configured to receive heat generated by the sensor
Implementation Method 3
convectively dissipate heat generated by the sensor
Data Source
AI summary
The subject matter described in this specification is directed to systems and methods for dissipating heat from sensors supporting autonomous vehicle systems. In particular, the specification describes how a housing, enclosing a sensor mounted to an exterior of a vehicle, can include heat dissipation components such as cooling fins across which conditioned cabin air and/or ambient air can be driven to convectively dissipate heat generated by the sensor.